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Manitowoc Indigo™ Series QuietQube Ice Machines Technician’s Handbook This manual is updated as new information and models are released. Visit our website for the latest manual. www.manitowocice.com America’s #1 Selling Ice Machine Part Number STH026 8/12 Safety Notices As you work on Manitowoc equipment, be sure to pay close attention to the safety notices in this handbook. Disregarding the notices may lead to serious injury and/or damage to the equipment. Throughout this handbook, you will see the following types of safety notices: ! Warning Text in a Warning box alerts you to a potential personal injury situation. Be sure to read the Warning statement before proceeding, and work carefully. Procedural Notices ! Caution Text in a Caution box alerts you to a situation in which you could damage the equipment. Be sure to read the Caution statement before proceeding, and work carefully. As you work on Manitowoc equipment, be sure to read the procedural notices in this handbook. These notices supply helpful information which may assist you as you work. Throughout this handbook, you will see the following types of procedural notices: Important Text in an Important box provides you with information that may help you perform a procedure more efficiently. Disregarding this information will not cause damage or injury, but it may slow you down as you work. Read These Before Proceeding: ! Caution Proper installation, care and maintenance are essential for maximum performance and troublefree operation of your Manitowoc equipment. If you encounter problems not covered by this manual, do not proceed, contact Manitowoc Foodservice. We will be happy to provide assistance. ! Caution Proper installation, care and maintenance are essential for maximum performance and troublefree operation of your equipment. Visit our website www.manitowocfsg.com for manual updates, translations, or contact information for service agents in your area. Important Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty. ! Warning Read this manual thoroughly before operating, installing or performing maintenance on the equipment. Failure to follow instructions in this manual can cause property damage, injury or death. ! Warning Do not use electrical appliances or accessories other than those supplied by Manitowoc for your ice machine model. ! Warning Two or more people or a lifting device are required to lift this appliance. ! Warning This equipment contains high voltage electricity and refrigerant charge. Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.The technician must also be certified in proper refrigerant handling and servicing procedures. All lockout and tag out procedures must be followed when working on this equipment. ! Warning Do not damage the refrigeration circuit when installing, maintaining or servicing the unit. ! Warning Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision concerning use of the appliance by a person responsible for their safety. Do not allow children to play with this appliance. ! Warning All covers and access panels must be in place and properly secured, before operating this equipment. ! Warning Do not obstruct machine vents or openings. ! Warning Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. ! Warning Do not clean with water jet. ! Warning It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures. ! Warning Two or more people are required to move this equipment to prevent tipping. ! Warning When using electric appliances, basic precautions must always be followed, including the following: a. Read all the instructions before using the appliance. b. To reduce the risk of injury, close supervision is necessary when an appliance is used near children. c. Do not contact moving parts. d. Only use attachments recommended or sold by the manufacturer. e. Do not use outdoors. f. For a cord-connected appliance, the following must be included: • Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord. • Unplug from outlet when not in use and before servicing or cleaning. • Do not operate any appliance with a damaged cord or plug, or after the appliance malfunctions or is dropped or damaged in any manner. Contact the nearest authorized service facility for examination, repair, or electrical or mechanical adjustment. g. Follow applicable lock out tag out procedures before working on equipment. h. Connect to a properly grounded outlet only. We reserve the right to make product improvements at any time. Specifications and design are subject to change without notice. Table of Contents General Information How to Read a Model Number . . . . . . . . . 15 Head Sections . . . . . . . . . . . . . . . . . . . 15 ICVD Condensing Units . . . . . . . . . . . . . . 16 Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . 16 Model/Serial Number Location . . . . . . . . 17 Model Numbers . . . . . . . . . . . . . . . . . . . . . 18 QuietQube® Models . . . . . . . . . . . . . . 18 Ice Machine Warranty Information . . . . . 19 Owner Warranty Registration Card . . . 19 Commercial Warranty Coverage . . . . . 20 Residential Ice Machine Warranty . . . . 22 Installation Stacking Two Ice Machines on a Single Storage Bin . . . . . . . . . . . . . . . 27 Ice Deflector . . . . . . . . . . . . . . . . . . . . 27 Location of Ice Machine . . . . . . . . . . . . . . 28 Head Section . . . . . . . . . . . . . . . . . . . . 28 Ice Beverage Models . . . . . . . . . . . . . 29 Location of ICVD Condensing Units . . 30 Clearance Requirements . . . . . . . . . . . . . 31 Ice Machine Heat of Rejection . . . . . . . . . 32 I1470C/I1870C/I2170C Installation on a Manitowoc Bin . . . . . . . 33 Ice Machine on a Dispenser Installation 34 Lineset Applications . . . . . . . . . . . . . . . . 35 QuietQube® Remote Condensing Unit . 36 ICVD Transformer Wiring . . . . . . . . . . 37 ICVD Interconnecting Wiring . . . . . . . . 37 Additional Refrigerant Charge For 51’ to 100’ Line Sets . . . . . . . . . . . . . . 38 Calculating Allowable Lineset Distance 39 Part Number STH026 8/12 9 Maintenance Cleaning and Sanitizing . . . . . . . . . . . . . 41 General . . . . . . . . . . . . . . . . . . . . . . . . 41 Cleaning/Sanitizing Procedure . . . . . . 43 Preventative Maintenance Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Exterior Cleaning . . . . . . . . . . . . . . . . 43 Cleaning / Sanitizing Procedure . . . . . . . 44 Cleaning Procedure . . . . . . . . . . . . . . 44 Sanitizing Procedure . . . . . . . . . . . . . 47 Parts Removal for Cleaning/Sanitizing 50 Operation Control Panel Features . . . . . . . . . . . . . . Buttons . . . . . . . . . . . . . . . . . . . . . . . . Display Panel . . . . . . . . . . . . . . . . . . . Menu Navigation Overview . . . . . . . . . . . Display Panel Navigation . . . . . . . . . . . . Alerts and Messages . . . . . . . . . . . . . . . . Main Menu . . . . . . . . . . . . . . . . . . . . . . . . Machine Info Menu . . . . . . . . . . . . . . . . . Reset Password To Factory Defaults . Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . Language . . . . . . . . . . . . . . . . . . . . . . Time & Date . . . . . . . . . . . . . . . . . . . . Time Configuration . . . . . . . . . . . . . . . Units . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Clarity . . . . . . . . . . . . . . . . . . . . . . LCD Brightness . . . . . . . . . . . . . . . . . Password Entry . . . . . . . . . . . . . . . . . . . . Clean Minder . . . . . . . . . . . . . . . . . . . IAuCS Runtime . . . . . . . . . . . . . . . . . . Air Filter . . . . . . . . . . . . . . . . . . . . . . . Water Filter . . . . . . . . . . . . . . . . . . . . . LuminIce™ reminder . . . . . . . . . . . . . Ice Bin Level Sensor . . . . . . . . . . . . . USB Setup . . . . . . . . . . . . . . . . . . . . . 10 61 61 62 63 64 66 67 68 68 69 70 70 72 72 73 73 74 75 76 76 77 78 79 79 Part Number STH026 8/12 Energy Saver Menu . . . . . . . . . . . . . . . . . 80 Ice Program . . . . . . . . . . . . . . . . . . . . . 81 Water Miser . . . . . . . . . . . . . . . . . . . . . 82 Statistics . . . . . . . . . . . . . . . . . . . . . . . 82 Factory Defaults . . . . . . . . . . . . . . . . . 83 Service Menu . . . . . . . . . . . . . . . . . . . . . . 84 Data History . . . . . . . . . . . . . . . . . . . . 86 Real Time Data . . . . . . . . . . . . . . . . . . 87 Diagnostics . . . . . . . . . . . . . . . . . . . . . 89 Manual Harvest . . . . . . . . . . . . . . . . . . 90 Replace Control Board . . . . . . . . . . . . 90 USB Setup . . . . . . . . . . . . . . . . . . . . . 90 Event Log Menu . . . . . . . . . . . . . . . . . 91 Event Log . . . . . . . . . . . . . . . . . . . . . . 92 USB Flash Drive Specifications and Formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Upgrading Firmware with a Flash Drive or Transferring Setup Data To Multiple Machines . . . . . . . . . . . . . . . . . . . . . . . . . 98 Exporting Data to a Flash Drive . . . . . 100 Operational Checks . . . . . . . . . . . . . . . . . 102 General . . . . . . . . . . . . . . . . . . . . . . . . 102 Ice Thickness Check . . . . . . . . . . . . . . 103 Sequence of Operation . . . . . . . . . . . . . . 104 QuietQube® Models . . . . . . . . . . . . . . 104 Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . 104 Freeze Sequence . . . . . . . . . . . . . . . . 105 Harvest Sequence . . . . . . . . . . . . . . . . 106 Automatic Shut-Off . . . . . . . . . . . . . . . 107 Restart After Automatic Shut-off . . . . . 107 Safety Timers . . . . . . . . . . . . . . . . . . . 110 Water Assist Harvest Feature . . . . . . . 110 Part Number STH026 8/12 11 Troubleshooting Safety Limits . . . . . . . . . . . . . . . . . . . . . . 111 Safe Operation Mode . . . . . . . . . . . . . 112 Analyzing Why a Safety Limit Stopped the Ice Machine . . . . . . . . . . . . . . . . . . . . 113 Safety Limit #1 . . . . . . . . . . . . . . . . . . 114 Safety Limit #2 . . . . . . . . . . . . . . . . . . 115 Troubleshooting By Symptom . . . . . . . . 116 Reset To Factory Defaults . . . . . . . . . 117 Symptom #1 Ice Machine will not run . 118 Diagnosing a Condensing Unit That Will Not Run . . . . . . . . . . . . . . . . 121 Symptom #2 Low Production, Long Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 122 Freeze Cycle Refrigeration System Operational Analysis Tables . . . . . . . . . . . . . 124 QuietQube® Models - Freeze Cycle Refrigeration System Operational Analysis Table Procedures . . . . . . . . . . . . . . . . . . . . . 130 Symptom #3 Harvest Problems . . . . . 148 Symptom #3 QuietQube® Models With ICVD Condensing Units . . . . . . . . . . . 149 Symptom #4 QuietQube® Models With ICVD Condensing Units . . . . . . . . . . . 153 12 Part Number STH026 8/12 Component Check Procedures Electrical Components . . . . . . . . . . . . . . . 155 Control Board, Display board and Touch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Control Board Relay Test . . . . . . . . . . 158 Programming A Replacement Board . . 159 Main Fuse . . . . . . . . . . . . . . . . . . . . . . 161 Bin Switch . . . . . . . . . . . . . . . . . . . . . . 162 Water Level Control Circuitry . . . . . . . 165 Ice Thickness Probe . . . . . . . . . . . . . . 171 High Pressure Cutout (HPCO) Control 176 Low Pressure Cutout (LPCO) Control . 179 Fan Cycle Control . . . . . . . . . . . . . . . . 180 Thermistors . . . . . . . . . . . . . . . . . . . . . 181 Harvest Assist Air Pump . . . . . . . . . . . 184 Compressor Electrical Diagnostics . . . 185 Diagnosing Start Components . . . . . . 187 Refrigeration Components . . . . . . . . . . . 190 Head Pressure Control Valve . . . . . . . 190 Suction Accumulator Operation . . . . . . 196 Recovery/Evacuation/Charging Procedures QuietQube® Models . . . . . . . . . . . . . . 197 Connections . . . . . . . . . . . . . . . . . . . . 198 Recovery/Evacuation Procedures . . . . 199 Charging Procedures . . . . . . . . . . . . . 200 System Contamination Clean-Up . . . . . . 201 Determining Severity Of Contamination 201 Cleanup Procedure . . . . . . . . . . . . . . . 203 Replacing Pressure Controls Without Removing Refrigerant Charge . . . . . . . . . 206 Liquid Line Filter-Driers . . . . . . . . . . . . 208 Suction Filter . . . . . . . . . . . . . . . . . . . . 208 Total System Refrigerant Charge . . . . 209 Part Number STH026 8/12 13 Charts Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts . . . . . . . . . . I0680C/ICVD0695 . . . . . . . . . . . . . . . IB0690C/ICVD695 . . . . . . . . . . . . . . . I0870C/ICVD895 . . . . . . . . . . . . . . . . IB0890C/ICVD895 . . . . . . . . . . . . . . . I1070C/ICVD1095 . . . . . . . . . . . . . . . IB1090C/ICVD1195 . . . . . . . . . . . . . . I1470C/ICVD1495 . . . . . . . . . . . . . . . I1870C/ICVD1895 . . . . . . . . . . . . . . . I2170C/ICVD2195 . . . . . . . . . . . . . . . 211 212 213 214 215 216 217 218 219 220 Diagrams Wiring Diagrams . . . . . . . . . . . . . . . . . . . 221 Wiring Diagram Legend . . . . . . . . . . . 221 All ICVD Models Interconnecting wiring 222 I0670C/I0870C/I1070C/I1270C . . . . . 223 IB0690C/IB0890C/IB1090C . . . . . . . . 224 II1400/I1800/I2170 . . . . . . . . . . . . . . . 225 iCVD2095 . . . . . . . . . . . . . . . . . . . . . . 226 Electronic Control Board . . . . . . . . . . . . 227 Refrigeration Tubing Schematics . . . . . 228 Remote Condensing Unit Models . . . . 228 IB Models . . . . . . . . . . . . . . . . . . . . . . 229 Dual Evaporator Models . . . . . . . . . . . 231 I2170C . . . . . . . . . . . . . . . . . . . . . . . . 232 14 Part Number STH026 8/12 Part Number STH026 8/12 Ice Machine Series ICE MACHINE MODEL I - Indigo Model IB - Ice Beverage ICE CUBE SIZE R - Regular D - Dice Y - Half-Dice Not Used On IB Models # HERTZ 5 - 50HZ 6 - 60HZ CONDENSER TYPE A - Self-Contained Air -Cooled W - Self-Contained Water -Cooled N - Remote Air-Cooled C - CVD Air-Cooled DC - IB Dice Model 3 - Three Phase YC - IB Half Dice E - WRAS 50 Cycle Only NO INDICATOR - 1 Phase 0 to 6 & 8 - Self-Contained Unit 7 & 8 - CVD Remote Condensing Unit 9 - Remote Air-Cooled Condenser OR 9 - Ice Beverage Remote Condensing Unit VOLTAGE 161 - 115/60/1 261 - 208-230 /60/1 251 - 230/50/1 263 - 208-230 /60/3 463 - 460/60/3 HP - High Pressure Water Regulating Valve X - LuminIce P - Correctional Model M - Marine Model I Y 0855 W3 – 263PHPX # CUBE SIZE CONDENSER TYPE 0 - Regular Air-Cooled 1 - Regular Water-Cooled 2 - Dice Air-Cooled 3 - Dice Water-Cooled 4 - Half-Dice Air-Cooled 5 - Half-Dice Water-Cooled 6 - Energy Plus Model General Information How to Read a Model Number HEAD SECTIONS 15 ICVD CONDENSING UNITS 5 AIR-COOLED ICVD 1495 3 CONDENSING UNIT MODEL CONDENSING UNIT SERIES 3 PHASE Ice Cube Sizes Regular Dice Half Dice 1-1/8" x 1-1/8" x 7/8" 7/8" x 7/8" x 7/8" 3/8" x 1-1/8" x 7/8" 2.86 x 2.86 x 2.22 cm 2.22 x 2.22 x2.22 cm 0.95 x 2.86 x 2.22 cm ! Warning Personal Injury Potential - Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision concerning use of the appliance by a person responsible for their safety. 16 Part Number STH026 8/12 ! Warning All Manitowoc ice machines require the ice storage system (bin, dispenser, etc.) to incorporate an ice deflector. Prior to using a non-Manitowoc ice storage system with other Manitowoc ice machines, contact the manufacturer to assure their ice deflector is compatible with Manitowoc ice machines. Model/Serial Number Location These numbers are required when requesting information from your local Manitowoc Distributor, service representative, or Manitowoc Ice, Inc. The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD. They are also listed on the MODEL/SERIAL NUMBER DECAL affixed to the front and rear of the ice machine. Part Number STH026 8/12 17 Model Numbers QUIETQUBE® MODELS Ice Machine Head Section ID0682C IY0684C IB0694YC ID0872C IY0874C IB0894YC ID1072C IY1074C IB1094YC ID1472C IY1474C ID1872C IY1874C ID2172C IY2174C 18 ICVD® Condensing Unit ICVD0695 ICVD0895 ICVD1095 ICVD1195 ICVD1495 ICVD1895 ICVD2095 Part Number STH026 8/12 Ice Machine Warranty Information OWNER WARRANTY REGISTRATION CARD Warranty coverage begins the day the ice machine is installed. Important Complete and mail the OWNER WARRANTY REGISTRATION CARD as soon as possible to validate the installation date. If the OWNER WARRANTY REGISTRATION CARD is not returned, Manitowoc will use the born on date recorded in the control board or the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice machine. Part Number STH026 8/12 19 COMMERCIAL WARRANTY COVERAGE Manitowoc Ice, (hereinafter referred to as the "COMPANY") warrants for a period of thirty-six months from the installation date (except as limited below) that new ice machines manufactured by the COMPANY shall be free of defects in material or workmanship under normal and proper use and maintenance as specified by the COMPANY and upon proper installation and start-up in accordance with the instruction manual supplied with the ice machine. The COMPANY'S warranty hereunder with respect to the compressor shall apply for an additional twentyfour months, excluding all labor charges, and with respect to the evaporator for an additional twenty-four months, including labor charges. The obligation of the COMPANY under this warranty is limited to the repair or replacement of parts, components, or assemblies that in the opinion of the COMPANY are defective. This warranty is further limited to the cost of parts, components or assemblies and standard straight time labor charges at the servicing location. Time and hourly rate schedules, as published from time to time by the COMPANY, apply to all service procedures. Additional expenses including without limitation, travel time, overtime premium, material cost, accessing or removal of the ice machine, or shipping are the responsibility of the owner, along with all maintenance, adjustments, cleaning, and ice purchases. Labor covered under this warranty must be performed by a COMPANY Contracted Service Representative or a refrigeration service agency as qualified and authorized by the COMPANY'S local Distributor. The COMPANY'S liability under this warranty shall in no event be greater than the actual purchase price paid by customer for the ice machine. 20 Part Number STH026 8/12 The foregoing warranty shall not apply to (1) any part or assembly that has been altered, modified, or changed; (2) any part or assembly that has been subjected to misuse, abuse, neglect, or accidents; (3) any ice machine that has been installed and/or maintained inconsistent with the technical instructions provided by the COMPANY; or (4) any ice machine initially installed more than five years from the serial number production date. This warranty shall not apply if the Ice Machine's refrigeration system is modified with a condenser, heat reclaim device, or parts and assemblies other than those manufactured by the COMPANY, unless the COMPANY approves these modifications for specific locations in writing. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OR GUARANTEES OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. In no event shall the COMPANY be liable for any special, indirect, incidental or consequential damages. Upon the expiration of the warranty period, the COMPANY'S liability under this warranty shall terminate. The foregoing warranty shall constitute the sole liability of the COMPANY and the exclusive remedy of the customer or user. To secure prompt and continuing warranty service, the warranty registration card must be completed and sent to the COMPANY within five (5) days from the installation date. To obtain warranty service or information regarding your Product, please contact us at: MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.manitowocice.com Part Number STH026 8/12 21 RESIDENTIAL ICE MACHINE WARRANTY WHAT DOES THIS LIMITED WARRANTY COVER? Subject to the exclusions and limitations below, Manitowoc Ice, Inc. (“Manitowoc”) warrants to the original consumer that any new ice machine manufactured by Manitowoc (the “Product”) shall be free of defects in material or workmanship for the warranty period outlined below under normal use and maintenance, and upon proper installation and startup in accordance with the instruction manual supplied with the Product. HOW LONG DOES THIS LIMITED WARRANTY LAST? Product Covered Warranty Period Ice Machine Twelve months from the sale date WHO IS COVERED BY THIS LIMITED WARRANTY? This limited warranty only applies to the original consumer of the Product and is not transferable. 22 Part Number STH026 8/12 WHAT ARE MANITOWOC ICE’S OBLIGATIONS UNDER THIS LIMITED WARRANTY? If a defect arises and Manitowoc receives a valid warranty claim prior to the expiration of the warranty period, Manitowoc shall, at its option: (1) repair the Product at Manitowoc’s cost, including standard straight time labor charges, (2) replace the Product with one that is new or at least as functionally equivalent as the original, or (3) refund the purchase price for the Product. Replacement parts are warranted for 90 days or the balance of the original warranty period, whichever is longer. The foregoing constitutes Manitowoc’s sole obligation and the consumer’s exclusive remedy for any breach of this limited warranty. Manitowoc’s liability under this limited warranty is limited to the purchase price of Product. Additional expenses including, without limitation, service travel time, overtime or premium labor charges, accessing or removing the Product, or shipping are the responsibility of the consumer. HOW TO OBTAIN WARRANTY SERVICE To obtain warranty service or information regarding your Product, please contact us at: MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.manitowocice.com Part Number STH026 8/12 23 WHAT IS NOT COVERED? This limited warranty does not cover, and you are solely responsible for the costs of: (1) periodic or routine maintenance, (2) repair or replacement of the Product or parts due to normal wear and tear, (3) defects or damage to the Product or parts resulting from misuse, abuse, neglect, or accidents, (4) defects or damage to the Product or parts resulting from improper or unauthorized alterations, modifications, or changes; and (5) defects or damage to any Product that has not been installed and/or maintained in accordance with the instruction manual or technical instructions provided by Manitowoc. To the extent that warranty exclusions are not permitted under some state laws, these exclusions may not apply to you. EXCEPT AS STATED IN THE FOLLOWING SENTENCE, THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY OF MANITOWOC WITH REGARD TO THE PRODUCT. ALL IMPLIED WARRANTIES ARE STRICTLY LIMITED TO THE DURATION OF THE LIMITED WARRANTY APPLICABLE TO THE PRODUCTS AS STATED ABOVE, INCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. 24 Part Number STH026 8/12 IN NO EVENT SHALL MANITOWOC OR ANY OF ITS AFFILIATES BE LIABLE TO THE CONSUMER OR ANY OTHER PERSON FOR ANY INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY KIND (INCLUDING, WITHOUT LIMITATION, LOSS OF PROFITS, REVENUE OR BUSINESS) ARISING FROM OR IN ANY MANNER CONNECTED WITH THE PRODUCT, ANY BREACH OF THIS LIMITED WARRANTY, OR ANY OTHER CAUSE WHATSOEVER, WHETHER BASED ON CONTRACT, TORT OR ANY OTHER THEORY OF LIABILITY. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. HOW STATE LAW APPLIES This limited warranty gives you specific legal rights, and you may also have rights that vary from state to state or from one jurisdiction to another. REGISTRATION CARD To secure prompt and continuing warranty service, this warranty registration card must be completed and sent to Manitowoc within thirty (30) days from the sale date. Complete the registration card and send it to Manitowoc. Part Number STH026 8/12 25 This Page Intentionally Left Blank 26 Part Number STH026 8/12 Installation ! Warning PERSONAL INJURY POTENTIAL Remove all ice machine panels before lifting. ! Warning I1470C/I1870C/I2170C ice machines are not approved for use on Manitowoc B570 bins. ! Caution The ice machine head section must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. STACKING TWO ICE MACHINES ON A SINGLE STORAGE BIN Indigo Model ice machines cannot be stacked. However an adapter is available that allows two QuietQube® ice machines to be placed side by side on 60” bins. ICE DEFLECTOR An ice deflector is required for all ice machines installed on a bin. Part Number STH026 8/12 27 Location of Ice Machine HEAD SECTION The location selected for the ice machine head section must meet the following criteria. If any of these criteria are not met, select another location. • The location must be free of airborne and other contaminants. • The air temperature must be at least 35°F (1.6°C), but must not exceed 110°F (43°C) • Ice Making Water Inlet - Water Pressure must be at least 20 psi (1.38 bar), but must not exceed 80 psi (5.52 bar). • The location must not be near heat-generating equipment or in direct sunlight and protected from weather. • The ice machine must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization” 28 Part Number STH026 8/12 ICE BEVERAGE MODELS • Ice/Beverage Ice Machines require that a proper ice level be maintained when installed on a dispenser. Ice Beverage machines ship with a ice level management sensor pre installed. • The ice machine head is installed with the electrical inlet, water supply inlet, refrigeration tubing and water drain entering from the back of the ice machine. • The ice machine head section contains a service loop that must remain installed between the ice machine head section and line set. Sufficient tubing length must be available to allow 180° rotation of the ice machine. • Maintain a 3” space between the back of the ice machine and the back of the dispenser to allow room for the refrigeration line set service loop. • The water inlet and electrical connection must contain a service loop to allow future service and maintenance access. • The drain line must contain a union or other suitable means of disconnection at the ice machine head section. • The location must be free of airborne and other contaminants. • The air temperature must be at least 35°F (1.6°C), but must not exceed 110°F (43°C). • The location must not be near heat-generating equipment or in direct sunlight. Part Number STH026 8/12 29 LOCATION OF ICVD CONDENSING UNITS The location selected for the ICVD Condensing Unit must meet the following criteria. If any of these criteria are not met, select another location. • ICVD0895/ICVD1095/ICVD1495/ICVD1895/ ICVD2195 Only - The air temperature must be at least -20°F (-28.9°C) but must not exceed 130°F (54.4°C). • ICVD695/ICVD1195/ICVD2195/ICVD3095 Only The air temperature must be at least -20°F (-28.9°C) but must not exceed 120°F (48.9°C). • The location must not allow exhaust fan heat and/ or grease to enter the condenser. • The location must not obstruct airflow through or around the condensing unit. See below for clearance requirements. 30 Part Number STH026 8/12 Clearance Requirements I0680C - I0870C I1070C - I2170C Ice Machine Head Section ICVD Condensing Unit *0” (0 cm) Top 5" (12.7 cm) Sides 5" (12.7 cm) *0” (0 cm) Back Standard Connections 5" (12.7 cm) 48” (122 cm) Back Connections Out Top 3” (7.6 cm) N/A Front *** 48” (122 cm) Ice Machine Head Section ICVD Condensing Unit *0” (0 cm) I1270C - I1470C I1870C Top 5" (12.7 cm) Sides 5" (12.7 cm) *0” (0 cm) Back Standard Connections 5" (12.7 cm) 48” (122 cm) Back Connections Out Top 3” (7.6 cm) N/A Front *** 24” (61.0 cm) Ice Machine Head Section ICVD Condensing Unit *0” (0 cm) Ice Beverage Models IB0690C - IB0890C IB1090C Top 2” (5.1 cm) Sides 8" (20.3 cm) *0” (0 cm) Back 5" (12.7 cm) 48” (122 cm) Front *** 48” (122 cm) *6” (15.2 cm) is recommended for servicing *** Minimum amounts vary by installation - Access is required for cleaning/sanitizing and ice removal Part Number STH026 8/12 31 Ice Machine Heat of Rejection Series Ice Machine Heat of Rejection Air Conditioning* Peak I0600 9000 13900 I0850 13000 16000 I1000 16250 18600 I1200 20700 24500 I1400 23500 27000 I1800 30000 35000 I2100 30500 35500 *BTU/Hour Because the heat of rejection varies during the ice making cycle, the figure shown is an average. 32 Part Number STH026 8/12 I1470C/I1870C/I2170C Installation on a Manitowoc Bin Dual evaporator models will not function correctly with the stock bin deflector. An ice deflector kit is required for installation and is ordered separate. Order appropriate kit (30” or 48”) for your bin. The stock bin deflector must be removed and replaced with the correct deflector to prevent injury. ! Warning PERSONAL INJURY POTENTIAL Do not operate any ice machine with the deflector removed. RE-INSTALL TOP COVER REMOVE DEFLECTOR Part Number STH026 8/12 REMOVE 1 SCREW ON EACH SIDE REMOVE 2 SCREWS ON EACH SIDE 33 A deflector must be installed on all dual evaporator models used in bin applications 2. LOCK IN PLACE WITH PIN 1. SLIDE FORWARD Ice Machine on a Dispenser Installation No deflector is needed for machines that match the size of the dispenser (30” head section on a 30” dispenser) unless required by the dispenser manufacturer. Adapters are required when a smaller ice machine is going on a larger dispenser (22” machine on a 30” dispenser) . Important Manitowoc Ice/Beverage Ice Machines require an adapter for mounting. Adapters are not included with the ice machine, dispenser or bin and must be ordered separately. When a nonManitowoc adapter is used, verify the adapter is compatible with Manitowoc Ice/Beverage Ice Machines prior to installation. ! Warning Ice Beverage ice machines, adapter plates and adapter covers must be secured to the dispenser to prevent tipping or dislodging during agitation 34 Part Number STH026 8/12 Lineset Applications ! Caution The 60-month compressor warranty (including the 36-month labor replacement warranty) will not apply if the Manitowoc Ice Machine, Condenser or QuietQube® Condensing Unit were not installed according to specifications. This warranty also will not apply if the refrigeration system is modified with a condenser, heat reclaim device, or other parts or assemblies not manufactured by Manitowoc Ice. ! Warning Recovery locations vary by model. Verify you are making the correct connections for your model to prevent accidental release of high pressure refrigerant. Important Manitowoc remote systems are only approved and warranted as a complete new package. Warranty on the refrigeration system will be void if new equipment is connected to preexisting (used) tubing, remote condenser, remote condensing unit or ice machine head section. Part Number STH026 8/12 35 QuietQube® Remote Condensing Unit QuietQube® Ice Machine Remote Single Circuit Condenser I0670C IB0670C ICVD0695 I0870C IB0870C ICVD0895 I1070C ICVD1095 IB1090C ICVD1195 I1470C ICVD1495 I1870C ICVD1895 I2170C ICVD2095 Line Set* RC-26 RC-36 RC-56 RC-25 RC-35 RC-55 RC-28 RC-38 RC-58 Minimum Insulation Thickness Suction Line Liquid Line RC 26/36/56 5/8 inch (16 mm) 3/8 inch (10 mm) 1/2" (13mm) Suction Line 1/4" (7mm) Liquid Line RC 25/35/55 3/4 inch (19 mm) 1/2 inch (13 mm) 1/2"(13mm) Suction Line 1/4" (7mm) Liquid Line RC 28/38/58 3/4 inch (19 mm) 5/8 inch (16 mm) 1/2"(13mm) Suction Line 1/4" (7mm) Liquid Line *Line Set 36 Part Number STH026 8/12 ICVD TRANSFORMER WIRING ICVD transformers leave the factory wired for a 240V supply voltage. When connecting to a 208V supply voltage, the transformer must be rewired to maintain a 24V secondary voltage. Failure to correctly wire the transformer can result in premature transformer failure. Refer to wiring diagrams for wiring details. ICVD INTERCONNECTING WIRING Important Indigo QuietQube ice machines require interconnecting low voltage wiring (included with Manitowoc line sets) to energize the contactor coil and verify the LPCO & HPCO are closed. This circuit also initiates a time delay whenever the LPCO or HPCO open. Failure to properly wire the iCVD condensing unit or ice machine head section will result in a non-operational machine. Wire Specifications: 18 AWG 5 Conductor, Single Strand, Plenum Rated, UL rated to 300 volts. Part Number STH026 8/12 37 Additional Refrigerant Charge For 51’ to 100’ Line Sets 38 Additional Amount of Refrigerant To Be Added To Nameplate Charge Ice Machine Condenser I0680C I0680C IB0690C ICVD0695 I0870C ICVD0895 4 lbs 1814 g IB890C ICVD0895 2 lbs 907 g I1070C ICVD1095 2 lbs 907 g IB1090C ICVD1195 2 lbs 907 g I1470C ICVD1495 2 lbs 907 g I1870C ICVD1895 2 lbs 907 g I2170C ICVD2095 2 lbs 907 g 1.5 lbs 680 g Part Number STH026 8/12 CALCULATING ALLOWABLE LINESET DISTANCE Line Set Length The maximum length is 100' (30.5 m). Line Set Rise/Drop The maximum rise is 35' (10.7 m). The maximum drop is 15' (4.5 m). S trap required at midpoint when Rise is 21’ or greater. 35 FT. (10.7 M) MAXIMUM DISTANCE SV1751 35 ft. (10.7 m) Rise: The maximum distance the Condenser or Condensing Unit can be above the ice machine. 15 FT. (4.5 M) MAXIMUM DISTANCE SV1750 15 ft. (4.5 m) Drop: The maximum distance the Condenser or Condensing Unit can be below the ice machine. Part Number STH026 8/12 39 Calculated Line Set Distance The maximum calculated distance is 150' (45.7 m). Line set rises, drops, horizontal runs (or combinations of these) in excess of the stated maximums will exceed compressor start-up and design limits. This will cause poor oil return to the compressor. Make the following calculations to make sure the line set layout is within specifications. 1. Insert the measured rise into the formula below. Multiply by 1.7 to get the calculated rise. (Example: A condenser located 10 feet above the ice machine has a calculated rise of 17 feet.) 2. Insert the measured drop into the formula below. Multiply by 6.6 to get the calculated drop. (Example. A condenser located 10 feet below the ice machine has a calculated drop of 66 feet.) 3. Insert the measured horizontal distance into the formula below. No calculation is necessary. 4. Add together the calculated rise, calculated drop, and horizontal distance to get the total calculated distance. If this total exceeds 150' (45.7 m), move the condenser to a new location and perform the calculations again. Maximum Line Set Distance Formula Step 1 Measured Rise ____ X 1.7 = ______Calculated Rise (35 ft. Max) Step 2 Measured Drop ____ X 6.6 = ______Calculated Drop (15 ft. Max.) Step 3 Measured Horizontal Distance = _________Horizontal (100 ft. Max.) Distance Step 4 Total Calculated Distance = ________Total Calculated (150 ft. Max.) Distance 40 Part Number STH026 8/12 Maintenance Cleaning and Sanitizing GENERAL You are responsible for maintaining the ice machine in accordance with the instructions in this manual. Maintenance procedures are not covered by the warranty. Clean and sanitize the ice machine every six months for efficient operation. If the ice machine requires more frequent cleaning and sanitizing, consult a qualified service company to test the water quality and recommend appropriate water treatment. An extremely dirty ice machine must be taken apart for cleaning and sanitizing. Manitowoc Ice Machine Cleaner and Sanitizer are the only products approved for use in Manitowoc ice machines. Part Number STH026 8/12 41 ! Caution Use only Manitowoc approved Ice Machine Cleaner and Sanitizer for this application (Manitowoc Cleaner part number 94-0546-3 and Manitowoc Sanitizer part number 94-0565-3). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Read and understand all labels printed on bottles before use. ! Caution Do not mix Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. ! Warning Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer. 42 Part Number STH026 8/12 CLEANING/SANITIZING PROCEDURE This procedure must be performed a minimum of once every six months. • The ice machine and bin must be disassembled cleaned and sanitized. • All ice produced during the cleaning and sanitizing procedures must be discarded. • Removes mineral deposits from areas or surfaces that are in direct contact with water. PREVENTATIVE MAINTENANCE CLEANING PROCEDURE • This procedure cleans all components in the water flow path, and is used to clean the ice machine between the bi-yearly cleaning/sanitizing procedure. EXTERIOR CLEANING Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation. Wipe surfaces with a damp cloth rinsed in water to remove dust and dirt from the outside of the ice machine. If a greasy residue persists, use a damp cloth rinsed in a mild dish soap and water solution. Wipe dry with a clean, soft cloth. The exterior panels have a clear coating that is stain resistant and easy to clean. Products containing abrasives will damage the coating and scratch the panels. • Never use steel wool or abrasive pads for cleaning. • Never use chlorinated, citrus based or abrasive cleaners on exterior panels and plastic trim pieces. Part Number STH026 8/12 43 Cleaning / Sanitizing Procedure ! Caution Use only Manitowoc approved Ice Machine Cleaner and Sanitizer for this application (Manitowoc Cleaner part number 94-0546-3 and Manitowoc Sanitizer part number 94-0565-3). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Read and understand all labels printed on bottles before use. CLEANING PROCEDURE ! Caution Do not mix Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. ! Warning Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer. Ice machine cleaner is used to remove lime scale and mineral deposits. Ice machine sanitizer disinfects and removes algae and slime. NOTE: Although not required and dependant on your installation, removing the ice machine top cover may allow easier access. 44 Part Number STH026 8/12 Step 1 Open the front door to access the evaporator compartment. Ice must not be on the evaporator during the clean/sanitize cycle. Follow one of the methods below: • Press the power switch at the end of a harvest cycle after ice falls from the evaporator(s). • Press the power switch and allow the ice to melt . ! Caution Never use anything to force ice from the evaporator. Damage may result. Step 2 Remove all ice from the bin/dispenser. Step 3 Press the clean switch. Water will flow through the water dump valve and down the drain. Wait until the water trough refills and the display indicates add solution (approximately 1 minute), then add the proper amount of ice machine cleaner. Model I0600/I0850/I1000/I1200 IB0690C/IB0890C/IB1090C I1400/I1800/I2100 Part Number STH026 8/12 Amount of Cleaner 5 ounces (150 ml) 9 ounces (265 ml) 45 Step 4 Wait until the clean cycle is complete (approximately 24 minutes). Then disconnect power to the ice machine (and dispenser when used). ! Warning Disconnect the electric power to the ice machine at the electric service switch box. Step 5 Remove parts for cleaning. Please refer to the proper parts removal for your ice machine. Continue with step 6 when the parts have been removed. Single Evaporator Ice Machines - page 50 Dual Evaporator Ice Machines - page 54 Step 6 Mix a solution of cleaner and lukewarm water. Depending upon the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly clean all parts. Solution Type Cleaner 46 Water Mixed With 1 gal. (4 L) 16 oz (500 ml) cleaner Part Number STH026 8/12 Step 7 Use 1/2 of the cleaner/water mixture to clean all components. The cleaner solution will foam when it contacts lime scale and mineral deposits; once the foaming stops use a soft-bristle nylon brush, sponge or cloth (NOT a wire brush) to carefully clean the parts. Soak parts for 5 minutes (15 - 20 minutes for heavily scaled parts). Rinse all components with clean water. Step 8 While components are soaking, use 1/2 of the cleaner/water solution to clean all food zone surfaces of the ice machine and bin (or dispenser). Use a nylon brush or cloth to thoroughly clean the following ice machine areas: • Side walls • Base (area above water trough) • Evaporator plastic parts - including top, bottom, and sides • Bin or dispenser Rinse all areas thoroughly with clean water. SANITIZING PROCEDURE Step 9 Mix a solution of sanitizer and lukewarm water. Solution Type Sanitizer Water Mixed With 3 gal. (12 L) 2 oz (60 ml) sanitizer Step 10 Use 1/2 of the sanitizer/water solution to sanitize all removed components. Use a spray bottle to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution. Do not rinse parts after sanitizing. Part Number STH026 8/12 47 Step 11 Use 1/2 of the sanitizer/water solution to sanitize all food zone surfaces of the ice machine and bin (or dispenser). Use a spray bottle to liberally apply the solution. When sanitizing, pay particular attention to the following areas: • Side walls • Base (area above water trough) • Evaporator plastic parts - including top, bottom and sides • Bin or dispenser Do not rinse the sanitized areas. Step 12 Replace all removed components. Step 13 Wait 20 minutes. Step 14 Reapply power to the ice machine and press the Clean button. 48 Part Number STH026 8/12 Step 15 Wait until the water trough refills and the display indicates add solution (approximately 1 minute). Add the proper amount of Manitowoc Ice Machine Sanitizer to the water trough by pouring between the water curtain and evaporator. Model I600/I0850/I1000/I1200 IB0690C/IB0890C IB1090C I1400/I1800/I2100 Amount of Sanitizer 3 ounces (90 ml) 3.5 ounces (104 ml) 12 ounces (355 ml) Step 16 Select auto ice on, press the checkmark and close and secure the front door. The ice machine will automatically start ice making after the sanitize cycle is complete (approximately 24 minutes). Part Number STH026 8/12 49 PARTS REMOVAL FOR CLEANING/SANITIZING Single Evaporator Ice Machines. E D A C B Off On / Off Mode [ ! ] A. Remove the water curtain • • Gently flex the curtain in the center and remove it from the right side. Slide the left pin out. B. Remove the water trough • • Depress tabs on right and left side of the water trough. Allow front of water trough to drop as you pull forward to disengage the rear pins. C. Remove the water level probe • • • • 50 Pull the water level probe straight down to disengage. Lower the water level probe until the wiring connector is visible. Disconnect the wire lead from the water level probe. Remove the water level probe from the ice machine. Part Number STH026 8/12 D. Remove the ice thickness probe • • Compress the hinge pin on the top of the ice thickness probe. Pivot the ice thickness probe to disengage one pin then the other. The ice thickness probe can be cleaned at this point without complete removal. If complete removal is desired, disconnect the ice thickness control wiring from the control board. E. Remove the water distribution tube NOTE: Distribution tube thumbscrews are retained to prevent loss. Loosen thumbscrews but do not pull thumbscrews out of distribution tube. • Loosen the two outer screws (do not remove screws completely they are retained to prevent loss) and pull forward on the distribution tube to release from slip joint. • Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing the distribution tube into two pieces. Proceed to page 47, Step 7 Part Number STH026 8/12 51 Ice Beverage Ice Machines B D E A C A. Remove splash shield • • Grasp the top center of splash shields. Lift up and then out. B. Remove ice thickness probe • • 52 Compress the hinge pin on the top of the ice thickness probe. Pivot the ice thickness probe to disengage one pin then the other. The ice thickness probe can be cleaned at this point without complete removal. If complete removal is desired, disconnect the ice thickness control wiring from the control board. Part Number STH026 8/12 C. Remove the water trough • • Depress tabs on right and left side of the water trough. Allow front of water trough to drop as you pull forward to disengage the rear pins. D. Remove the water level probe • • • • Pull the water level probe straight down to disengage. Lower the water level probe until the wiring connector is visible. Disconnect the wire lead from the water level probe. Remove the water level probe from the ice machine. E. Remove the water distribution tube NOTE: Distribution tube thumbscrews are retained to prevent loss. Loosen thumbscrews but do not pull thumbscrews out of distribution tube. • Loosen the two outer screws (do not remove screws completely they are retained to prevent loss) and pull forward on the distribution tube to release from slip joint. Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing the distribution tube into two pieces NOTE: Proceed to page 47, Step 7. Part Number STH026 8/12 53 Dual Evaporator Ice Machines A B C D E F A.Remove front splash shield • • Grasp the top of the splash shield. Lift up and then out. B. Remove evaporator splash shields • • Grasp the top center of splash shields. Lift up and then out. C. Remove the water trough shield • • • 54 Grasp the water trough shield in the center and the left end. Flex the water trough shield in the center and pull the left end forward until clear of the side wall. Repeat for the right end. Pull water trough shield forward to remove. Part Number STH026 8/12 D. Remove ice thickness probe • • Compress the hinge pin on the top of the ice thickness probe. Pivot the ice thickness probe to disengage one pin then the other. The ice thickness probe can be cleaned at this point without complete removal. If complete removal is desired, disconnect the ice thickness control wiring from the control board. E. Remove distribution tubes • • • Distribution tubes thumbscrews are retained to prevent loss. Loosen thumbscrews but do not pull thumbscrews out of distribution tube. Loosen the two outer screws and pull forward on the distribution tube to release from slip joint. Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing the distribution tube into two pieces. F. Remove the water trough • Depress the two tabs on the top of the water trough. • Turn left and right ice dampers down to clear water trough. • Pull forward on the water trough to remove. NOTE: Proceed to page 47, Step 7. Part Number STH026 8/12 55 Ice Thickness Probe & Water Level Probe Clean the probes using the following procedure. 1. Mix a solution of Manitowoc ice machine cleaner and water (2 ounces of cleaner to 16 ounces of water) in a container. 2. Soak probes in container of cleaner/water solution while disassembling and cleaning water circuit components (soak probes for 10 minutes or longer). 3. Clean all probe surfaces including all plastic parts (do not use abrasives). Verify all surfaces are clean. Thoroughly rinse probes with clean water. 4. Reinstall probe, then sanitize the ice machine and bin/dispenser interior surfaces. 56 Part Number STH026 8/12 Water Inlet Valve The water inlet valve normally does not require removal for cleaning. Refer to “Water System Checklist” page 134, if you are troubleshooting water related problems. 1. When the ice machine is off, the water inlet valve must completely stop water flow into the machine. Watch for water flow. When the ice machine is on, the water inlet valve must allow the proper water flow through it. Press the Power button to energize the ice machine. Watch for water flow into the ice machine. If the water flow is slow or only trickles into the ice machine, refer to water system checklist. ! Warning Disconnect the electric power to the ice machine and dispenser at the electric service switch box and turn off the water supply before proceeding. Follow the procedure below to remove the water inlet valve. 1. Remove the 1/4” hex head screws. 2. Remove, clean, and install the filter screen. 4 Hex Head Screws Part Number STH026 8/12 57 Water Dump Valve The water dump valve normally does not require removal for cleaning. To determine if removal is necessary: 1. Locate the water dump valve. 2. Press the power button and stop ice making. 3. While the ice machine is in the freeze mode, check the water trough to determine if the dump valve is leaking. If there is no or little water in the water trough (during the freeze cycle) the dump valve is leaking. A. If the dump valve is leaking, remove, disassemble and clean it. B. If the dump valve is not leaking, do not remove it. Instead, follow the “Ice Machine Cleaning Procedure”. Follow the procedure below to remove the dump valve. ! Warning Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply before proceeding. 4. If so equipped, remove the water dump valve shield from its mounting bracket. 5. Leaving the wires attached, twist coil and rotate it counter-clockwise1/4 turn. 6. Lift the coil assembly off the valve body. 7. Remove the spring, plunger, and nylon gasket from the valve body. NOTE: At this point, the water dump valve can easily be cleaned. If complete removal is desired, continue with step 5. Important The plunger and the inside of the enclosing tube must be completely dry before assembly. 58 Part Number STH026 8/12 NOTE: During cleaning, do not stretch or damage the spring. 1. Remove the tubing from the dump valve by twisting the clamps off. 2. Remove the valve body, twist off. COIL SPRING PLUNGER NYLON GASKET DIAPHRAM MOUNTING BRACKET VALVE BODY Dump Valve Disassembly Part Number STH026 8/12 59 This Page Intentionally Left Blank 60 Part Number STH026 8/12 Power Button Cleaning Button Manitowoc LCD Display Navigation Arrows Menu Button Checkmark Operation Control Panel Features The control panel offers a series of pressure sensitive buttons and a four-line interactive display panel. BUTTONS Power Button: Powers the ice machine when in the On/Off Mode. The ice machine can also be programmed to automatically power on and off in two Energy Saver modes. Cleaning Button: Initiates a cleaning cycle. Refer to the Maintenance section for details. Part Number STH026 8/12 61 Menu Button: Accesses main menu structure. Moves the display from the Home Screen, where ice machine status, alerts and messages are viewed, to the Main Menu, where machine information and its event log can be accessed, machine and Energy Saver settings can be adjusted, and service issues can be addressed. Left and Right Arrows: The Left arrow moves the display to the previous screen, allowing the user to “back out” of programming. Both the Left and Right arrows will move the cursor (underline) within a line of settings. NOTE: The Right arrow can also be used on many screens interchangeably with the checkmark to make a selection. Up and Down Arrows: Move the highlight [brackets] up one line or down one line. Checkmark: Makes a selection and/or moves to the next screen (or line) and is used like an “enter” button. DISPLAY PANEL The LCD display panel is 16 characters wide and four lines deep. During ice machine operation and cleaning cycles, the Home screen’s top three lines provide valuable status information and the fourth line shows alerts and messages. In programming, four lines of the current screen are displayed and highlights, arrows, cursor and selections inform the user of available actions. 62 Part Number STH026 8/12 Menu Navigation Overview Menu Button ON/OFF Button Timer Initiated Cleaning Button Home Screen When Alert Present When Message Present Alerts Messages AuCS Clean Function Clean Function Main Menu Machine Info Energy Saver Set-up Password Entry (Optional) 90/70 Capacity Model Number Ice Machine Head Serial Number Condenser Serial Number Warranty Install Date Manufacture Date Main Software Version Display Software Version Exit Language Time/Date Time Config Units Ice Clarity LCD Brightness Password On Edit Password Clean Minder AuCS Run Time Air Filter Water Filter LUMINICE Ice Bin Sensor USB Setup Exit Defaults Service EXIT Defaults Exit Ice Program Water Miser Statistics Exit Press to power ON/OFF Return to Home Screen Data History Real Time Data Diagnostics Manual Harvest Replace Control Board USB Setup Event Log Exit Press to access cleaning function Press to access Main Menu Press to select menu/sub-menu option Navigate Menus Part Number STH026 8/12 63 Display Panel Navigation [Language Time & Date Time Config Units >]▼ > > > ▼ Highlights: Brackets indicate if a line on the screen is “highlighted” or actionable. Move the brackets from line to line using the Down or Up arrow. Move the brackets down from the fourth line to view more of the menu displayed. Arrows: Two kinds of arrows give cues to additional information. “>” symbols show that another screen is available by pressing Checkmark or > while a line is highlighted. “▼” and “▲” symbols indicate the limits of the screen viewed. NOTE: Another cue to the length of a menu screen is that Exit is the last item. 07 24 10 14:08 Exit 64 > Part Number STH026 8/12 Cursor: A cursor (flashing rectangle) is used within lines where actual settings can be adjusted. In these screens, use the Up and Down arrows to make changes to the value underlined. Move the cursor from digit to digit using the Right and Left arrows. Use the Checkmark to move the cursor down one line. Exit and re-enter the screen to start again at the top. [Mo/Day/Yr Day/Mo/Yr 12 Hour 24 Hour ( ( ( ( )]▼ ) ) ) ▼ Selections: When parentheses ( ) appear, they indicate a selection is available by pressing Checkmark while the line is highlighted. If the choice is exclusive, selecting it with the Checkmark will uncheck another selection. That is, in the above Time Config example, selecting Day/Mo/Yr will deselect Mo/Day/ Yr. Part Number STH026 8/12 65 Alerts and Messages When messages and alerts exist, they will be highlighted and can be selected with the Left arrow. Alerts displayed will have priority over messages. Off On / Off Mode [< ! ] For example, if alerts are appearing in the fourth line of the display: 1. Press the Left arrow. A list of alerts will appear in the display. 2. Choose the alert you wish to address by moving the highlight brackets with the Down arrow. 3. Press Checkmark again. A screen appears with the date, time and total number of times an alert has occurred. Pressing the Down arrow will list some possible causes for the alert. At the bottom of the screen you will be able to clear the alert by pressing the Checkmark. 4. Return to the Home screen by selecting Exit and pressing the Checkmark. 66 Part Number STH026 8/12 Main Menu From the Home screen, press the Menu button to enter the Main menu, where you can choose to see machine information, make setup changes, set the Energy Saver mode, or enter the Service Menu. Machine Info Set-Up Energy Saver Factory Defaults Service Exit Main Menu Part Number STH026 8/12 67 Machine Info Menu From the Main menu, ensure that Machine Info is highlighted and press the Checkmark to view a list including capacity, model number, IMH (Ice Machine Head) serial number, condenser serial number, warranty, installation date, date of manufacture and software version. Use the Down arrow to highlight an item and use the Checkmark to view the information. Press the Left arrow to return to previous screens Machine Info Menu • 90/70 capacity • Model # • Ice Machine Head Serial # • Condenser Serial # • Warranty • Machine • Evaporator • Compressor • Install Date • Manufacture Date • Main Control Board Software Version • Display Software Version RESET PASSWORD TO FACTORY DEFAULTS The password can be reset to the factory defaults when required. The default factory password is 1234. To reset the ice machine to factory defaults refer to page 80. 68 Part Number STH026 8/12 Set-Up Menu From the Main menu, use the Down arrow to navigate to Set-Up and press the Checkmark. Select and customize machine settings on this menu. Press the Left arrow to return to previous screens. Set-Up Language Time & Date Time Configuration Units Ice Clarity LCD Bright Password On Edit Password Clean Minder AuCS RunTime Air Filter Water Filter LUMINICE Ice Bin Sensor USB Setup Exit Set-Up Menu Part Number STH026 8/12 69 LANGUAGE 1. From the Set-Up menu, use the Down arrow to highlight Language. 2. Press the Checkmark. You can choose to view the display in a language other than English, by highlighting your choice and pressing the Checkmark. Selecting one language will deselect the others. 3. When the check reflects your preference, use the Down arrow to navigate to Exit and press the Checkmark. The display will return to the Set-Up menu. TIME & DATE When the ice machine is installed, the correct time and date needs to be set for its location. [Mo/Day/Yr Day/Mo/Yr 12 Hour 24 Hour ( ( ( ( )]▼ ) ) ) ▼ Set the Time and Date 1. Press the Menu button. 2. Press the Down arrow until Set-Up is highlighted [bracketed]. 3. Press the Checkmark. The Set-Up menu will be displayed and Time & Date will be highlighted [bracketed]. 70 Part Number STH026 8/12 4. Press the Checkmark. The date will appear on the first line of the display (Mo/Day/Yr) and the time will appear on the second line (24 Hour). The month will have a blinking cursor. 5. Using the Up or Down arrow, adjust the month, if necessary. 6. When the correct month appears, use the Right arrow to move the blinking cursor to day. 7. Using the Up or Down arrow, adjust the day, if necessary. 8. When the correct day appears, use the Right arrow to move the blinking cursor to year. 9. Using the Up or Down arrow, adjust the year, if necessary. 10. When the correct year appears, press the Checkmark. Use the Right arrow to move the blinking cursor to hour. 11. Using the Up or Down arrow, adjust the hour, if necessary. 12. When the correct hour appears, use the Right arrow to move the blinking cursor to minutes. 13. Using the Up or Down arrow, adjust the minutes, if necessary. 14. When the correct minutes appear, press the Checkmark twice. Part Number STH026 8/12 71 TIME CONFIGURATION 1. From the Set-Up menu, use the Down arrow to highlight Time Config. 2. Press the Checkmark. On this screen, you can choose whether the date will be displayed as Mo/Day/Yr or Day/Mo/Yr by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. You can also choose whether the time will be displayed as 12 Hour or 24 Hour by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 4. When the two checks reflect your preference, use the Down arrow to navigate to Exit and press the Checkmark. The display will return to the Set-Up menu. UNITS 1. From the Set-Up menu, use the Down arrow to highlight Units. 2. Press the Checkmark. On this screen, you can choose whether the ice machine will display measurements in Celsius or Fahrenheit, kilograms or pounds, and gallons or liters by highlighting your choice of each pair and pressing the Checkmark. Selecting one of each pair will deselect the other. Make sure to navigate with the Down arrow to make all three choices. 3. When the three checks reflect your preferences, use the Down arrow to navigate to Exit and press the Checkmark. The display will return to the SetUp menu. 72 Part Number STH026 8/12 ICE CLARITY In areas with poor potable water quality, the ice machine may produce cloudier ice. Setting Ice Clarity to ON will add additional water during the freeze cycle to dilute the water that contains a high content of dissolved solids in the water trough. This feature decreases production and increases water usage. A water filter is recommended to produce the highest quality ice while maintaining the least expensive mode of operation. 1. From the Set-Up menu, use the Down arrow to highlight Ice Clarity. 2. Press the Checkmark. On this screen, you can choose to turn the ice clarity feature ON or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. When the check reflects your preference, use the Down arrow to navigate to Exit and press the Checkmark. The display will return to the Set-Up menu. LCD BRIGHTNESS Here, the brightness of the LCD display can be adjusted. 1. From the Set-Up menu, use the Down arrow to highlight LCD Bright. 2. Press the Checkmark. You will see one of four checkmarks indicating the brightness levels of the display. Level 1 is one checkmark, level 2 is two checkmarks, Level 3 is three checkmarks, etc. 3. Use the Up and Down arrows to select your preference. 4. When the checkmarks reflect your preference, press the Checkmark. The display will return to the Set-Up menu. Part Number STH026 8/12 73 Password Entry A password is not required, although a password can be turned on to prevent unauthorized control setting modification. You can use the Factory Default Password of "1234" or enter a four digit custom pin number of your choosing. To turn on the password feature use the following procedure. 1. Press the Menu button. 2. From the Main menu, use the Down arrow to highlight setup and press the Right arrow. 3. Use the Down arrow to highlight Password ON and press the Right arrow. 4. Press the Right arrow again with Enter Passwrd highlighted and a cursor will flash. 5. Use the Up & Down arrows to enter the factory password (1, 2, 3, 4). Enter the number 1 in the flashing cursor (first digit of the factory password). 6. Press the right arrow to move to the next cell and use the Up & Down arrows to add the number 2. Repeat this process to add 3 & 4. 7. When the last number is entered press the Checkmark button to save your entry. Enter Passwrd ▲ [ ] Exit > 74 Part Number STH026 8/12 To enter a four digit password of your choosing use the following procedure. 1. Press the Menu button. 2. From the Main menu, use the Down arrow to highlight setup and press the Right arrow. 3. Use the Down arrow to select Edit Password and press the Right arrow. 4. Using the Up & Down arrows, enter the first digit of the factory password in the flashing icon. 5. Press the right arrow to move to the next cell and use the Up & Down arrows to add the number 2. Repeat this process to add 3 & 4. 6. When the last number is entered press the Checkmark button. 7. Follow steps 4 & 5 and enter your 4 digit password. 8. When the last number is entered press the Checkmark button to save your entry. CLEAN MINDER Clean Minder is a feature that displays a cleaning reminder at a set time interval. 1. From the Set-Up menu, use the Down arrow to highlight Clean Minder. 2. Press the Checkmark. On this screen, you can choose to turn the reminder ON or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. You can also choose the time interval from this screen by highlighting Set Interval and pressing the Checkmark. 4. Press the Left arrow to return to previous screens and to the Set-Up menu. Part Number STH026 8/12 75 IAUCS RUNTIME Automatic Cleaning System is an optional accessory and will perform a cleaning cycle at a set time interval. 1. From the Set-Up menu, use the Down arrow to highlight AuCS RunTime. 2. Press the Checkmark. On this screen, you can choose to turn the feature ON or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. You can also choose the time interval from this screen by highlighting Set Interval and pressing the Checkmark. 4. Press the Left arrow to return to previous screens and to the Set-Up menu. AIR FILTER The ice machine has a feature that displays a clean air filter reminder at a set time interval. 1. From the Set-Up menu, use the Down arrow to highlight Air Filter. 2. Press the Checkmark. On this screen, you can choose to turn the reminder to AUTO or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. You can also choose the time interval from this screen by highlighting Set Interval and pressing the Checkmark. 4. Press the Left arrow to return to previous screens and to the Set-Up menu. 76 Part Number STH026 8/12 WATER FILTER The ice machine has a feature that displays a replace water filter reminder at a set time interval. 1. From the Set-Up menu, use the Down arrow to highlight Water Filter. 2. Press the Checkmark. You can record the filter type on this screen by highlighting Filter Type and pressing the Checkmark. After making your selection (AR10,000, AR20,000, AR40,000), scroll down to exit and press the Checkmark. 3. You can also choose to turn the reminder to AUTO, NONE or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. • Selecting Auto sets the reminder based on water usage for the selected filter. • Selecting None will turn off the reminder. • Selecting Off sets the timer to the selected reminder time (2 weeks to 6 months). 4. You can further choose the time interval from this screen by highlighting Set Interval and pressing the Checkmark. 5. Press the Left arrow to return to previous screens and to the Set-Up menu. Part Number STH026 8/12 77 LUMINICE™ REMINDER The LuminIce™ growth inhibitor recirculates the air in the ice machine foodzone over a UV bulb. This process will inhibit the growth of common microorganisms on all exposed foodzone surfaces. The Bulb Minder is a feature that displays a reminder to change its bulb every 12 months. 1. From the Set-Up menu, use the Down arrow to highlight LuminIce Minder. 2. Press the Checkmark. On this screen, you can choose to turn the reminder to AUTO or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. When the check reflects your preference, use the Down arrow to navigate to Exit and press the Checkmark. The display will return to the Set-Up menu. 78 Part Number STH026 8/12 ICE BIN LEVEL SENSOR Ice bin sensor is an optional accessory that allows the ice level in the bin to be set to one of three different levels. The bin level can be set seasonally to match usage, which results in lower energy costs and fresher ice. 1. From the Set-Up menu, use the Down arrow to highlight Ice Bin Sensor. 2. Press the Checkmark. On this screen, you can choose to set the ice level to Low, Medium or High by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. When the check reflects your preference, use the Down arrow to navigate to Exit and press the Checkmark. The display will return to the Set-Up menu. USB SETUP Refer to “Upgrading Firmware with a Flash Drive” and “Exporting Data to a Flash Drive” for more information on this setting. Flash drives must be correctly sized and formatted - 2 gigabytes or smaller, Fat 32 file system, 512 allocation units - Refer to page 94 for full specification and formatting details. Part Number STH026 8/12 79 Energy Saver Menu From the Main menu, use the Down arrow to navigate to Energy Saver and press the Checkmark. Set up an energy saving ice program, enable the Water Miser and view usage statistics from this menu. Press the Left arrow to return to previous screens. Energy Saver Ice Program Water Miser Statistics Exit Energy Saver Menu 80 Part Number STH026 8/12 ICE PROGRAM To save energy and water, the ice machine can be programmed to only power up during time periods that the ice will be used or when the bin level is being depleted by heavy use. 1. In the Energy Saver menu, ensure that Ice Program is highlighted. 2. Press the Checkmark. On this screen, you can choose to turn on the time program (Time Prog) bin level program (Bin Level) or ice usage program (Ice Program) by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. If one of them is selected and you wish to turn both off, highlight the choice and press Checkmark again. 3. If none of the programs are selected, highlighting Settings and pressing the Checkmark will select the times, bin level or pounds of ice per day. If one of the programs is selected, highlight Settings and press the Checkmark to choose the times or bin levels. NOTE: For details on how to use the cursor for the time program, refer to “Display Panel Navigation” in this section. 4. Select Exit to return to previous screens and again to the Energy Saver menu. Part Number STH026 8/12 81 WATER MISER Water Miser is a feature that depending on water quality can reduce water usage by eliminating flush cycles. 1. From the Energy Saver menu, use the Down arrow to highlight Water Miser. 2. Press the Checkmark. On this screen, you can choose to turn the Water Miser ON or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. Use the Down arrow to navigate to Exit and press the Checkmark to return to the Energy Saver menu. STATISTICS 1. From the Energy Saver menu, use the Down arrow to highlight Statistics. 2. Press the Checkmark. Choose to view ice usage, or potable water and energy statistics by highlighting your choice and pressing the Checkmark. 3. Press the Left arrow to return to previous screens and to the Energy Saver menu. 82 Part Number STH026 8/12 FACTORY DEFAULTS The entire setup can be reset to the factory defaults. 1. From the Set-Up menu, use the Down arrow to highlight Fact Deflts. 2. Press the Checkmark two times to reset the ice machine. The display will return to the Set-Up menu. Setting Language Time Configuration Units Ice Clarity LCD Brightness Password Edit Password Clean Minder AuCS RunTime Air Filter Minder Water Filter Minder LuminIce Bulb Minder Ice Bin Sensor Part Number STH026 8/12 Default English Mo/Day/Yr/24 Hour Fahrenheit/Lbs/Gallons Off Level 2 Off - Enter Password Default Password = 1234 Off - Edit Password Off Off Off Auto No None 83 Service Menu From the Main menu, use the Down arrow to navigate to Service and press the Checkmark. This menu is intended for the use of trained service personnel. Below is an overview of the service menu. The following pages list the navigation options available by drilling into the menus with the Right arrow. Service Data History 00000000 00000000 00000000 00000000 00000000 00000000 Lifetime Exit RealTime Data Time & Temp Inputs Outputs Exit Diagnostics Control Board Temp Sensors Inputs Exit Man Harvest Hrvst Started Exit Repl Cntl Bd Manual Setup USB Setup Exit USB Setup USB Stick Exit Event Log View ELog Clear ELog Exit Exit 84 Part Number STH026 8/12 Part Number STH026 8/12 85 Current Day Current Day Current Day Current Day Current Day Current Day Lifetime Data History -1 -2 -3 -4 -5 Time & Temp Inputs Outputs Real Time Data Control Board Temp Sensors Input Diagnostics USB Stick Manual Setup USB Setup Harvest Started Download Frm Download Cnf Export ALL Export Setup USB Setup Repl Cnt Bd Manual Harvest Service View E Log Clear E Log Event Log DATA HISTORY Press the Checkmark with Data History highlighted to view a list of eight-digit dates (Current, Current + 1 ... Current + 5), along with Lifetime (be sure to use the Down arrow to reveal all the available information). For each of the dates, use the Checkmark to view: • Minimum Freeze • Maximum Freeze • Minimum Harvest • Maximum Harvest • Maximum Temperature Delta T3 - T4 • Delta • T3 • T4 • RunTime • Ice Production • Cycle Count • Potable Water • Clean Cycles • Exit For Lifetime, use the Checkmark to view: • Install Date • Control Board Replacement Date • Control Board DOM (Date Of Manufacture) • RunTime • Cycle Count • Potable Water • Clean Cycles • Exit 86 Part Number STH026 8/12 REAL TIME DATA Press the Checkmark with Real Time Data highlighted to get readings on Time & Temp, Inputs and Outputs (be sure to use the Down arrow to reveal all the available information). Use the Checkmark to view: Time and Temperature • Status Off/On - Displays stage of cycle • Time • T1 Thermistor Temperature • T2 Thermistor Temperature • T3 Thermistor Temperature • T4 Thermistor Temperature • T3 & T4 Delta Temperature • 100 hz • 120 hz • Exit Inputs • Status Off/On - Displays stage of cycle • Curtain Switch 1 • Curtain Switch 2 • LPCO Switch • HPCO Switch • Bin Level - Low (Optional Bin Level Probe) Status • Bin Level - Medium (Optional Bin Level Probe) Status • Bin Level High (Optional Bin Level Probe) Status • Sensing Ice No/Yes • Water Level Low No/Yes • Water Level High No/Yes • Exit Part Number STH026 8/12 87 Outputs • Status Off/On - Displays stage of cycle • Water Pump Off/On • Hot Gas Valve 1 Off/On • Hot Gas Valve 2 Off/On • Air Pump Off/On • Water Valve Off/On • Dump Valve Off/On • Compressor Control Off/On • AuCS Relay Off/On • Ionic Cln Off/On • Exit 88 Part Number STH026 8/12 DIAGNOSTICS Press the Checkmark with Diagnostics highlighted to enter screens where you can run diagnostics on the control board, sensors and switches. Control Board • Self Check • Enable Relays • Exit Temperature Sensors • T1 Thermistor Temperature • T2 Thermistor Temperature • T3 Thermistor Temperature • T4 Thermistor Temperature • Exit Inputs • Curtain Switch 1 Closed/Open • Curtain Switch 2 Closed/Open • LPCO Switch Closed/Open • HPCO Switch Closed/Open • Bin Level - Low (Optional Bin Level Probe) Closed/ Open • Bin Level - Medium (Optional Bin Level Probe) Closed/Open • Bin Level - High (Optional Bin Level Probe) Closed/Open • Sensing Ice No/Yes • Water Level Low No/Yes • Water Level High No/Yes • Exit Part Number STH026 8/12 89 MANUAL HARVEST Press the Checkmark with Manual Harvest highlighted to initiate a manual harvest. Manual Harvest • Harvest Started • Exit REPLACE CONTROL BOARD Press the Checkmark with Replace Control Board highlighted to program the replacement control board. The data can copied from the defective control board (refer to “Exporting Data to a Flash Drive” on page 100), or entered manually through the Indigo interface. • Manual Setup • Board Install Date • Input Model Number • Input Serial Number • Condenser/condensing unit serial number • USB Setup • Insert Drive • Press Checkmark and wait for completion • Exit USB SETUP • USB Stick • Download Firmware Insert drive and wait for completion • Download Configuration Insert drive and wait for completion • Export All Insert drive and wait for completion • Export Setup Insert drive and wait for completion • Exit 90 Part Number STH026 8/12 EVENT LOG MENU From the Service menu, use the Down arrow to navigate to Event Log and press the Checkmark. Ensure View ELog is highlighted and press the Checkmark to see the first event code, when it occurred and how many times. Use the Down arrow to view information on subsequent event codes. For more information on event codes, see “Service Menu”. Use the Left arrow to return to the Event Log menu. To clear the event log: In the Event Log Menu, use the Down arrow to highlight Clear ELog and press the Checkmark. Press the Left arrow to return to previous screens. Event Log View ELog Clear ELog Exit Event Log Menu Part Number STH026 8/12 91 EVENT LOG Refer to the following table for Event Code descriptions. Code Description E01 Long Freeze Cycle E02 Long Harvest Cycle E03 Input Power Loss E04 High Condenser Temperature E05 High Pressure Control Opened E06 Spare E07 Starving TXV Single Evaporator or Low On Charge E08 TXV Fault Single or Dual Circuit Evaporators E09 Flooding Evaporator Fault Single Evaporator, Single Circuit E10 Flooding Evaporator Fault Dual TXV, Dual Circuit E11 Refrigeration Fault E12 Curtain Switch Fault - E Board = Open more than 12 hours, G Board after Revision 4.017 = Open more than 24 hours E13 Spare E14 Spare E15 Fan Cycle Control Fault - Lo Liquid Line Temperature E16 Remote Condensing Unit Fault (ICVD Only) E17 Spare E18 Spare E19 Ice Thickness Probe Fault E20 Water System Fault E21 T1 Temperature Sensor Issue E22 T2 Temperature Sensor Issue E23 T3 Temperature Sensor Issue E24 T4 Temperature Sensor Issue E25 Bin Level Probe Low Sensor Fault E26 Bin Level Probe Medium Sensor Fault E27 Bin Level Probe High Sensor Fault E28 AuCS E29 USB Communication Fault E30 USB Download Fault E31 Safe Mode E32 RS485 Communication Fault E33 KeyBoard Fault E34 Display Fault 92 Part Number STH026 8/12 Part Number STH026 8/12 Event Log Detail Detail Event Log Service Definition E-Log Display Text E01 Long Freeze E02 Long Harvest E03 Power Loss E04 Hi Cnd Temp or Wtr Cnd Fault E05 HPC Fault E06 Error Description Long Freeze Definition Long Harvest 3 consecutive - 3.5 Minute Harvests logs SL#2 in memory, but runs until 500 long harvest cycles occur. Power Supply (Event Log only No Alert) Air Condenser High temp, or water Condenser High temperature G Board Rev 4.017 - Alert only after 10 consecutive trips When power is interrupted to the ice machine the control board will log the event in the ELOG and stamp the loss of power on power-up. 1). Liquid Line Temperature too High for Self-contained Air Cooled Ice machine = Air Cooled Condenser Fault 2). Liquid Line Temperature too High for Self-contained Water Cooled ice machine = Water Cooled Condenser Fault The high pressure cutout switch (HPCO) opened 3 times in 4 hour period High Pressure Cutout (HPC) 6 consecutive 60 Minute Freeze cycles = shut down and flash the SL#1 light on board Spare Starving Evaporator for single TXV or low on charge G Board Rev 4.017 Event Log only no alert 10 consecutive occurrences where the Difference of the Average evaporator inlet (T3) and outlet (T4) is greater than 12°F in the last 1 minute of the freeze cycle (ELOG-E07) 93 E07 Starving TXV E08 TXV Fault Air/Water Only TXV malfunction in dual circuit/ single evaps (TXV Fault) 10 consecutive occurrences where the Difference of the Average evaporator inlet (T3) and outlet (T4) is greater than 12°F in the last 1 minute of the freeze cycle (ELOG-E07) E09 Flood Evap 1 Flooding evaporator for single circuit single evaporator (flooding evap) Average compressor discharge line temperature last 6 seconds of Prechill +50°F (T1) compared to average of first 6 minutes of freeze cycle (T2), is less than 1.05°F E10 Flood Evap 2 Flooding evaporator for dual TXV dual circuit / single evaporator (Flooding Evap) Average compressor discharge line temperature last 6 seconds of Prechill +50°F (T1) compared to average of first 6 minutes of freeze cycle (T2), is less than 1.05°F 94 Detail Event Log Service Definition E-Log Display Text E11 Refig Fault Error Description Definition Refrigeration System (Refrig Fault) The compressor discharge temperature did not increase by at least 10 F, and the evaporator temperature did not decreased by at least 10 F - Measured from Refrigeration Start up or Prechill until 2 minutes into the Freeze cycle. G Board Rev 4.017 - Event Log only no alert Air & Water-cooled Only E12 Curtain Fault E13 Curtain Switch open for more than 24 hours (Curtain Fault) The ice machine is set to ice making and remains in bin full condition for more than 24 hours. The curtain switch is open or curtain is off. G Board Rev 4.017 = 24 hrs - E Board = 12 hrs Spare E14 Spare Part Number STH026 8/12 Low amb control fault durring low amb If the liquid line temperature drops below 60 F for any period exceeding continuous 1 minute during the the freeze cycle. G Board Rev 4.017 - Event Log only no alert If the liquid line temperature drops below 40 F, or exceeds 140 F for more than 1 continuous minute during the freeze cycle. G Board Rev 4.017 - Event Log only no alert E17 Remote Condenser Fault ICVD Condensing Unit only Spare E18 Spare E15 Low Liq Temp E16 Rmt Cnd Fault E19 ITP Fault Ice Probe (ITP) E20 WTR Fault Water System Fault The monitored Frequencies is out of the appropriate range (Probe unplugged or problem with microphone). G Board Rev 4.017 - Event Log only no alert Any of the following: 1) Sensing high water probe and not low water probe = Water fault. 2) The Evaporator outlet temperature is less than -10°F 6.5 to 7.5 Minutes into freeze. 3) The Low Water probe is satisfied at the end of harvest. 4) Low or High water probe satisfied at end of freeze cycle. G Board Rev 4.017 - Event Log only no alert Part Number STH026 8/12 Detail Event Log Service Definition E-Log Display Text Error Description E21 T1 Fault T1 Sensor E22 T2 Fault T2 Sensor E23 T3 Fault T3 Sensor E24 T4 Fault T4 Sensor Definition Each thermistor reading is monitored continuously using six second average values. During Pre-chill a thermistor had a six second average thermistor values fall outside of the valid temperature range. E25 Bin Prb Fault Bin Low Sens E26 Bin Prb Fault Bin Med Sens E27 Bin Prb Fault Bin Hi Sens E28 AUCS AUCS (Aucs not Present) (Event Log only - No alarm) E29 USB COMM USB Comm (Event Log only - No Alarm) USB Communication error, no USB drive in port or defective USB drive E30 USB DNLD USB download error (dlnd) Event Log only - No alarm) USB Download error related to USB drive or a defective USB drive E31 Safe Mode Safe Mode (Event Log only - No alarm) Each thermistor reading is monitored continuously using six second average values. A thermistor had a six second average value outside of the valid range for more than 10 continous minutes When the AUCS clean option is selected from the menu, the control checks for the presence of the AUCS board and if the AUCS is not connected it will signal an Event “AUCS”. This will be cleared as soon as the hardware is detected. Safe mode allows the ice machine to operate for a period of time in the event of a WLP or ITP sensor failure. The controller allows the machine to operate based on historical information collected and model data information stored in the controllers memory. 95 USB FLASH DRIVE SPECIFICATIONS AND FORMATTING Updating firmware on Indigo™ model ice machines requires a properly formatted 2 GB or smaller USB flash drive. All USB flash drives must be formatted before use to remove any software programs or files currently on the flash drive. USB Flash Drive Specifications: • USB 2 Version • 2 GB or less capacity • Fat32 File System • 512 MB File Allocation Unit USB Flash Drive Formatting: Procedure to format a USB flash drive varies with operating system software. Windows 7 or Windows Vista Computers: 1. Insert USB flash drive; your computer may indicate: • “Found New Hardware” follow the prompts to install the USB flash drive • USB flash drive may auto play - Close auto play window 2. Press Windows Key and E key simultaneously to access windows explorer. 3. Right click on your USB Flash Drive. 4. Left click on “Format”. 5. Verify or select the settings below: • USB flash drive capacity - 2 GB or less • File System - Fat32 • Allocation Unit Size - Must be 512 MB • Volume Label is Optional - Rename if desired • Deselect “Perform A Quick Format” (no checkmark) 6. Left click on “Start” - You will receive a warning “Formatting will remove all data” left click “OK”. A “Format Complete” box will display when formatting is finished. Close the pop up and windows explorer. 96 Part Number STH026 8/12 Windows XP Computers: 1. Insert USB flash drive; your computer may indicate: • “Found New Hardware” follow the prompts to install the USB flash drive • USB flash drive may auto launch - Close auto launch window. 2. To access Disk Management: • Left click on the Windows Start Button • Left click on “Run” • Type compmgmt.msc and left click on “OK” • Left click on “Disk Management”. 3. Verify USB flash drive capacity is 2 GB or less 4. Right click on the USB flash drive, then left click on “Format” from the drop down list. 5. Verify or select the settings below: • Volume Label is Optional - Rename if desired • File System - Fat32 • Allocation Unit Size must be 512 MB • Deselect “Perform A Quick Format” (no checkmark) 6. Left click on “OK” you will receive a warning “Formatting will remove all data” left click on “OK”, wait until formatting is complete and “status” indicates “Healthy”, then close the disk management window. Part Number STH026 8/12 97 UPGRADING FIRMWARE WITH A FLASH DRIVE OR TRANSFERRING SETUP DATA TO MULTIPLE MACHINES Important The flash drive must be formatted before using, All files and software on the flash drive are removed during the formatting process. Refer to page 94 USB Flash Drive Specifications and Formatting. 1. Drag and drop the files from your email onto a flash drive or refer to Exporting data to a flash drive to transfer settings to multiple machines. 2. Ensure that the ice machine’s power is on. 3. Press the Menu button. 4. Press the Down arrow until Service is highlighted. 5. Press the Checkmark. The Service menu will be displayed. USB Setup USB Stick Download Frm 6. Press the Down arrow until USB Setup is highlighted. 7. Press the Checkmark. USB Stick will appear highlighted. 8. Press the Checkmark again. A submenu with Download Frm (Download Firmware) appears. 9. Ensure that Download Frm is highlighted and press the Checkmark. A display of instructions will appear. 98 Part Number STH026 8/12 Bin Switches Bin Thermostat USB Display Light Micro Light Clean Light Harvest Light SL-1 Light SL-2 Light Thermistors T1 T2 Dump Valve T3 T4 USB Connector Left Bin Switch Light Transformer Right Bin Switch Light Water Level Probe Light Display Ice Thickness Probe Light RS485 RT Harvest Bin LED LuminIce Battery Compressor LT Harvest Water Level Probe Fuse Relay Lights Pump Control Board 10. Follow the on-screen instructions: A. Insert Drive (Insert the flash drive into the USB port on the ice machine’s control board.) B. Press Check (Press the Checkmark.) C. Wait For Comp (Wait approximately 5 to 10 minutes for the Firmware upgrade to complete. 11. Upgrade Complete will appear on the display 12. Verify the new firmware version loaded by navigating to Menu/Machine information/Main Software Version and verify the firmware version number. Part Number STH026 8/12 99 EXPORTING DATA TO A FLASH DRIVE Data can be copied from the control board memory to a flash drive and used to transfer setup and/or cycle data to a replacement control board or to transfer setup information to multiple ice machines. Data may also be requested by service department personnel for analysis or as an aid to troubleshooting. The data files are small and can be attached to an email. Important The flash drive must be formatted before using, Refer to page 96 USB Flash Drive Specifications and Formatting. All files and data are deleted during the formatting process. 1. 2. 3. 4. Ensure that the ice machine’s power is on. Press the Menu button. Press the Down arrow until Service is highlighted. Press the Checkmark. The Service menu will be displayed. USB Setup USB Stick Export All 5. Press the Down arrow until USB Setup is highlighted. 100 Part Number STH026 8/12 6. Press the Checkmark. USB Stick will appear highlighted. 7. Press the Checkmark again. A submenu with Export ALL and Export Setup appears. 8. Highlight Export ALL or Export Setup, depending on your requirements, and press the Checkmark. A display of instructions will appear. 9. Follow these on-screen instructions to: A. Insert Drive (Insert the flash drive into the USB port on the ice machine’s control board.) B. Press Check (Press the Checkmark.) C. Wait For Comp (Wait approximately 5 to 10 minutes for the download to complete. D. Depending on software version either Export Complete, Success or the On/Off screen will appear. Part Number STH026 8/12 101 Operational Checks GENERAL Manitowoc ice machines are factory-operated and adjusted before shipment. Normally, new installations do not require any adjustment. To ensure proper operation, always follow the Operational Checks: • when starting the ice machine for the first time • after a prolonged out of service period • after cleaning and sanitizing NOTE: Routine adjustments and maintenance procedures are not covered by the warranty. Important Refrigeration compressors must be operated for a minimum break in period of 24 hours before full ice production will be reached. 102 Part Number STH026 8/12 ICE THICKNESS CHECK After a harvest cycle, inspect the ice cubes in the ice storage bin. The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8" (3 mm). NOTE: Make sure the water curtain or splash shield is in place when performing this check. It prevents water from splashing out of the water trough. 1. Inspect the bridge connecting the cubes. It should be about 1/8" (3 mm) thick. 2. If adjustment is necessary, turn the ice thickness probe adjustment screw clockwise to increase bridge thickness, counterclockwise to decrease bridge thickness. As a starting point place a 9/32" (7 mm) drill bit between the ice thickness probe and the evaporator. Make final adjustments to achieve a 1/8" (3 mm) thick bridge. NOTE: Turning the adjustment 1/3 of a turn will change the ice thickness about 1/16" (1.5 mm). 1/8" (3 mm) ICE BRIDGE THICKNESS PLACE 9/32” DRILL BIT HERE TO SET INTIAL Ice Thickness Check 3. Make sure the ice thickness probe wire doesn’t restrict movement of the probe. Part Number STH026 8/12 103 Sequence of Operation QUIETQUBE® MODELS NOTE: The power button must be depressed and the water curtain/ice dampers must be in place on the evaporator before the ice machine will start. INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF 1. Water Purge Before the compressor starts, the water pump and water dump solenoid are energized to purge the ice machine of old water. This feature ensures that the ice making cycle starts with fresh water. 2. Refrigeration System Start-Up Ice Machine Head Section: The harvest valve(s), air pump(s), liquid line solenoid valve and CVD relay energize to equalize high and low side refrigeration pressure. After 10 seconds the harvest valve(s) and air pump(s) de-energize. ICVD Condensing Unit: The low pressure switch closes and sends 24 volts to the control board. The control board completes the circuit through the CVD relay and sends 24 volts to the contactor coil and energizes the compressor. 104 Part Number STH026 8/12 FREEZE SEQUENCE 3. Prechill The compressor lowers the temperature of the evaporator(s) before the water pump is energized. The water fill valve will energize and remain on until water completes the water level probe circuit. 4. Freeze The water pump(s) energizes and water flows over the evaporator. After water contacts the water level probe the water fill valve de-energizes. The control board will automatically cycle the water fill valve fill time limit. The valve energizes once in the pre-chill and up to twice in the freeze cycle. The freeze cycle continues until the six minute freeze lock expires and enough ice has formed to send a signal from the ice thickness probe to the control board. Part Number STH026 8/12 105 HARVEST SEQUENCE 5. Water Purge The air pump(s) and the harvest valve(s) open at the beginning of the water purge to divert refrigerant gas into the evaporator. The water pump continues to run, and the water dump valve energizes to purge the water in the water trough. ICVD Condensing Unit: When the refrigerant pressure is low enough to open the fan cycling pressure control the condenser fan motor stops. 6. Harvest The air pump(s) remain energized and the harvest valve(s) remains open. The refrigerant gas warms the evaporator causing the cubes to begin melting and slide, as a sheet, off the evaporator and into the storage bin. Single evaporator models - The sliding sheet of cubes opens the water curtain/ice damper and bin switch. The momentary opening and re-closing of the bin switch will terminate the harvest sequence and return to the freeze sequence (Step 3 - 4.) Twin evaporator models - The sliding sheet of cubes opens the ice damper and bin switch. The momentary opening and re-closing of the bin switch de-energizes the harvest valve for that evaporator. When the bin switch has opened and closed the ice machine will terminate the harvest sequence and return to the freeze sequence (Step 3 - 4.) 106 Part Number STH026 8/12 AUTOMATIC SHUT-OFF 7. Automatic Shut-Off Ice Machine Section: Shuts off when: • The storage bin is full at the end of a harvest sequence. • The sheet of cubes fails to clear the water curtain and holds it open. • Ice damper is held down. • Bin level probe thermistor senses setpoint (when used). After the water curtain or ice damper are held open for 30 seconds, the ice machine shuts off. The ice machine remains off for 10 minutes before it can automatically restart. ICVD Condensing Unit: The liquid line solenoid valve closes and the condensing unit pumps down. The LPCO opens and signals the control board. The control board starts a ten minute delay period and opens the 24 VAC circuit to the contactor coil, stopping the compressor and condenser fan motor. RESTART AFTER AUTOMATIC SHUT-OFF The ice machine remains off until enough ice has been removed to allow the ice to fall clear of the water curtain or ice damper. As the water curtain or ice damper swings back to the operating position, the bin switch re-closes and the ice machine restarts (steps 1 - 2), provided the 10 minute delay period is complete. Part Number STH026 8/12 107 Part Number STH026 8/12 Single & Twin Evaporator QuietQube® Models Energized Parts Chart Ice Making Sequence of Operation Start-Up - Initial or After Auto Shut Off 1. Water Purge 2. Refrigeration System Start-up Pressure Equalization Compressor Start Water Pump Harvest Valve (s) Air Pumps Water Inlet Valve Water Dump Valve Liquid Line Solenoid Valve Contactor Refrigeration Compressor & Condenser Fan Motor* Length of Time On Off Off Off On Off Off 45 Seconds Off On On Off Off Off Off 5 Seconds Off On On Off Off On On 5 Seconds Off Off Off May cycle On/Off Off On On Initial Start-Up is 60 Seconds 30 Seconds thereafter On Off Off Cycles Off then On/ Off, two more times Off On On Until Ice contact with ice thickness probe Freeze Sequence 3. Pre chill 4. Freeze 108 Part Number STH026 8/12 Single & Twin Evaporator QuietQube® Models Energized Parts Chart (Continued) Water Pump Harvest Valve (s) Air Pumps Water Inlet Valve Water Dump Valve Liquid Line Solenoid Valve Contactor Refrigeration Compressor & Condenser Fan Motor* Length of Time On On On Off On On On Factory-set at 45 Seconds 6. Harvest Off On On Off Off On On Bin switch activation 7. Automatic Shut-Off Off Off Off Off Off Off Off Until 3 min. delay expires & all bin switches re-close Ice Making Sequence of Operation Harvest Sequence 5. Water Purge * The condenser fan motor is controlled by a fan cycle control, therefor it may cycle on/off. 109 SAFETY TIMERS The control board has the following non-adjustable safety timers: • The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated. This can be overridden by initiating a manual harvest. Refer to “Manual Harvest” on page 90 • The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence (steps 5 & 6). • The maximum harvest time is 3.5 minutes at which time the control board automatically ends the harvest cycle. When the bin switch is closed a freeze sequence initiates (steps 3 & 4). When the bin switch is open an automatic shutoff sequence initiates. • The maximum water fill is 12.5 minutes (16.5 minutes for dual evaporator models). WATER ASSIST HARVEST FEATURE Twin Evaporators Only: Typical duration of a Harvest sequence is less than 2.5 minutes. When the Harvest sequence time reaches 4 minutes, the following occurs: 4 minutes into a Harvest sequence: The water fill valve will energize to fill the trough with water. 5 minutes into a Harvest sequence: The water pump will energize and flow water over the evaporators. The water fill valve and water pump remain on until all bin switches have been activated, or until the 7-minute Harvest sequence time limit is reached. 110 Part Number STH026 8/12 Troubleshooting Safety Limits In addition to standard safety controls, the control board has built in safety limit controls which protect the ice machine from major component failures. Safety limits are stored and indicated by the control board after three cycles. The number of cycles required to stop the ice machine varies for each safety limit. • Safety Limit 1 all models - If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle. If 6 consecutive 60-minute freeze cycles occur, the ice machine stops • Safety Limit 2 single evaporator models - If the harvest time reaches 3.5 minutes, the control board automatically returns the ice machine to the freeze cycle. If 500 consecutive 3.5 minute harvest cycles occur, the ice machine stops. • Safety Limit 2 Dual evaporator models - If the harvest time reaches 7 minutes, the control board automatically returns the ice machine to the freeze cycle. If 500 consecutive 7 minute harvest cycles occur, the ice machine stops. Part Number STH026 8/12 111 SAFE OPERATION MODE Allows the ice machine to operate up to 72 hours if the ice thickness probe (E19 fault) and/or water level probe sensors fail (E20 fault). • When the control board starts the safe mode an alert is flashed on the LCD display to notify the end-user they have a production problem. • The control board automatically initiates and monitors the safe mode. The control will automatically exit the safe mode if a normal signal is received from the input. • After 72 hours the control board will enter a standby mode and turn off NOTE: The control board needs a five cycle history to operate safe mode. If five cycles have never been successfully completed the ice machine will shut-off. • Example - The ice machine is a new installation and the water has not been turned on. The ice machine will stop after five cycles with five long freeze cycles and five water system faults in the event log. 112 Part Number STH026 8/12 ANALYZING WHY A SAFETY LIMIT STOPPED THE ICE MACHINE Safety limits are designed to stop the ice machine prior to major component failures, most often a minor problem or something external to the ice machine. This may be difficult to diagnose, as many external problems occur intermittently. Example: An ice machine stops intermittently on safety limit #1 (long freeze times). The problem could be a low ambient temperature at night, a water pressure drop, the water is turned off one night a week, etc. Refrigeration and electrical component failures will cause a safety limit trip. Eliminate all electrical components and external causes first. If it appears that the refrigeration system is causing the problem, use Manitowoc’s Freeze Cycle Refrigeration System Operational Analysis Table, along with detailed charts, checklists, and other references to determine the cause. The following checklists are designed to assist the service technician in analysis. However, because there are many possible external problems, do not limit your diagnosis to only the items listed. Part Number STH026 8/12 113 SAFETY LIMIT #1 Freeze time exceeds 60 minutes for 6 consecutive freeze cycles. Possible cause list Improper Installation • Refer to “Installation/Visual Inspection Checklist” page 133 Water System • Defective water level probe • Low water pressure (20 psig min.) • High water pressure (80 psig max.) • High water temperature (90°F/32.2°C max.) • Clogged water distribution tube • Dirty/defective water fill valve • Dirty/defective water dump valve • Defective water pump • Loss of water from sump area Electrical System • Low incoming voltage • Ice thickness probe out of adjustment • Harvest cycle not initiated electrically • Contactor not energizing • Compressor electrically non-operational • Defective fan cycling control • Defective fan motor Miscellaneous • Non-Manitowoc components • Improper refrigerant charge • Defective head pressure control • Defective harvest valve • Defective compressor • TXV starving or flooding (check bulb mounting) • Non-condensable in refrigeration system • Plugged or restricted high side refrigerant lines or component • Restricted air flow/dirty condenser fins • High inlet air temperature • Condenser discharge air recirculation 114 Part Number STH026 8/12 SAFETY LIMIT #2 Single Evaporator Models - Harvest time exceeds 3.5 minutes for 500 consecutive harvest cycles Dual Evaporator Models - Harvest time exceeds 7 minutes for 500 consecutive harvest cycles Possible Cause Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” page 133 Water System • Water area (evaporator) dirty • Dirty/defective water dump valve • Vent tube not installed on water outlet drain • Water freezing behind evaporator • Plastic extrusions and gaskets not securely mounted to the evaporator • Clogged water distribution tube Electrical System • Ice thickness probe out of adjustment • Bin switch closed/defective • Premature harvest Refrigeration System • Non-Manitowoc components • Improper refrigerant charge • Defective head pressure control valve • Defective harvest valve • TXV flooding (check bulb mounting) • Defective fan cycling control Part Number STH026 8/12 115 Troubleshooting By Symptom The troubleshooting procedures follow flow charts. There are four symptoms, the symptom that you are experiencing will determine which flow chart to use. The flow chart asks yes and no questions to determine the problem. The flow chart will direct you to a procedure to correct the problem. QuietQube® remote condensing units use separate charts. SYMPTOM #1 Ice Machine Stops Running Ice machine is in Ice Making cycle or Has a History of Shutting Down • Refer to Ice Machine Stops Running Flow Chart SYMPTOM #2 Ice Machine has a Long Freeze Cycle. Ice Formation is Thick or Thin Ice Fill on inlet or outlet of Evaporator or Low Production Safety Limit #1 (possible) • Refer to Freeze Cycle Refrigeration System Operational Analysis Table SYMPTOM #3 Ice Machine Will Not Harvest - Freeze Cycle is Normal and Ice Cubes are Not Melted After Harvest Safety Limit #2 (possible) • Refer to Refrigeration Harvest Flow Chart SYMPTOM #4 Ice Machine Will Not Harvest - Freeze Cycle is Normal and Ice Cubes are Melted After Harvest • Refer to Ice Meltout Flow Chart 116 Part Number STH026 8/12 RESET TO FACTORY DEFAULTS Before starting troubleshooting procedures, reset the control board to factory defaults to prevent misdiagnosis. Before resetting to factory defaults do one of the following: A. Copy settings to a usb device and flash settings into the control board when diagnostics are complete. B. Write down any customer settings so they can be re-entered when diagnostics are complete. This procedure also resets the password to the factory default. The default factory password is 1234. To reset the ice machine to factory defaults See “Reset Password To Factory Defaults” on page 68. Part Number STH026 8/12 117 118 SYMPTOM #1 ICE MACHINE WILL NOT RUN START Is the display interface energized and functioning? Does the ice machine start when the Power button is pushed? Yes Yes Is there an Alert or Error Logged? Yes Install Ground No Micro light flashing? No Part Number STH026 8/12 Are there any lights on or flashing on the control board? Unit has adequate ground? Refer to display & control board diagnostics No Refer to Alert/Error Log No No No Yes No No Yes Cycle Power to Board, are lights flashing? Display light Flashing? Yes Yes Yes Refer to display & control board diagnostics Part Number STH026 8/12 Yes Line voltage at wires 55 & 56 on 9 pin control board connector? No Supply power to the ice machine Yes Install the water curtain/damper. Yes No Control board fuse is good? Yes No Replace fuse & determine which component caused fuse to blow Bin switch light on? (Multi evap all lights on?) No All water curtains or dampers in place? Refer to display & control board diagnostics Yes Yes 119 120 Yes Yes No Press power button to start ice making, does safety limit light flash? Is magnet on the water curtain/damper Yes No Part Number STH026 8/12 Refer to display & control board diagnostics Ice machine starts? Yes Yes Which light flashes? Test run ice machine SL1 SL2 No Replace the water curtain/damper. Refer to bin switch diagnostics. Refer to Safety Limit #1 long freeze cycle Refer to Safety Limit #2 long harvest cycle DIAGNOSING A CONDENSING UNIT THAT WILL NOT RUN If the ice machine water pump is not energized, refer to “Diagnosing an Ice Machine that Will Not Run. Also see “All ICVD Models Interconnecting wiring” on page 222 1. Verify primary voltage is supplied to ice machine condensing unit and the fuse/circuit breaker is closed. 2. Test for 24 vac at terminals C & V - Replace transformer if 24 vac is not present. 3. Verify the low-pressure control is closed by testing for 24 vac @ terminals C & LPC. 4. Verify wires are intact and ice machine is calling for cooling by testing for 24 vac @ terminals C & HPC1. 5. Verify the high-pressure control is closed by testing for 24 vac at the contactor coil terminals. 6. Verify the contactor contacts are closed and line voltage is present across all lines. 7. Refer to compressor diagnostics. Part Number STH026 8/12 121 SYMPTOM #2 LOW PRODUCTION, LONG FREEZE CYCLE Ice Machine has a Long Freeze Cycle. Ice Formation is Thick or Thin ice fill at Inlet or Outlet of Evaporator or Low Production How to Use the Freeze Cycle Refrigeration System Operational Analysis Table GENERAL These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear defective. The tables list five different defects that may affect the ice machine’s operation. NOTE: A low-on-charge ice machine and a starving expansion valve have very similar characteristics and are listed under the same column. NOTE: Before starting, see “Before Beginning Service” for a few questions to ask when talking to the ice machine owner. 122 Part Number STH026 8/12 PROCEDURE Step 1 Complete the “Operation Analysis” column. Read down the left “Operational Analysis” column. Perform all procedures and check all information listed. Each item in this column has supporting reference material to help analyze each step. While analyzing each item separately, you may find an “external problem” causing a good refrigerant component to appear bad. Correct problems as they are found. If the operational problem is found, it is not necessary to complete the remaining procedures. Step 2 Enter Checkmarks (). Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a Checkmark. Example: Freeze cycle suction pressure is determined to be low. Enter a Checkmark in the “low” column. Step 3 Add the Checkmarks listed under each of the four columns. Note the column number with the highest total and proceed to “Final Analysis.” NOTE: If two columns have matching high numbers, a procedure was not performed properly, supporting material was not analyzed correctly or the problem component is not covered by the analysis table. Part Number STH026 8/12 123 124 Freeze Cycle Refrigeration System Operational Analysis Tables I Model QuietQube® Single Expansion Valve Operational Analysis Ice Production Installation and Water System Part Number STH026 8/12 Ice Formation Pattern See “QuietQube® Models Ice Formation Pattern” on page 135 1 2 3 4 Published 24 hour ice production________________ Calculated (actual) ice production_______________ NOTE: The ice machine is operating properly if the ice fill patterns is normal and ice production is within 10% of charted capacity. See “QuietQube® Models - Ice Production Check” on page 131 All installation and water related problems must be corrected before proceeding with chart. See “QuietQube® Models - Installation/Visual Inspection Checklist” on page 133 Ice formation is extremely thin on outlet of evaporator -orNo ice formation on the entire evaporator Ice formation normal -orIce formation is extremely thin on outlet of evaporator -orNo ice formation on entire evaporator Ice formation normal -orIce formation is extremely thin on inlet of evaporator -orNo ice formation on entire evaporator Ice formation normal -orNo ice formation on entire evaporator Part Number STH026 8/12 I Model QuietQube® Single Expansion Valve Operational Analysis 1 2 3 4 Safety Limits Refer to “Analyzing Safety Limits” page 113 to eliminate all non-refrigeration problems. Stops on safety limit: 1 or 2 Stops on safety limit: 1 or 2 Stops on safety limit: 1 or 2 Stops on safety limit: 1 Freeze Cycle Discharge Pressure If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure _______ ______ ______ problem checklist page 139 & page 140 to eliminate problems and/or components not listed on 1 minute Middle End this table before proceeding. into cycle Freeze Cycle Suction Pressure _______ ______ _____ 1 minute Middle End Harvest Valve If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist page 138 & page 143 to eliminate problems and/or components not listed on this table before proceeding. Suction pressure is High Suction pressure is Low or Normal Suction pressure is Normal or High Suction pressure is High Audible refrigerant flow through harvest valve in Freeze cycle No audible refrigerant flow through harvest valve in Freeze cycle No audible refrigerant flow through harvest valve in Freeze cycle No audible refrigerant flow through harvest valve in Freeze cycle 125 126 I Model QuietQube® Single Expansion Valve Operational Analysis 1 2 3 4 Suction Line Temperature Attach a temperature probe on the suction line with-in 6" of the shut-off valve outlet. Record the low event at the end of the freeze cycle Suction line temp. at the suction shut-off valve is greater than 10°F (-12.2°C) at the end of the freeze cycle Suction line temp. at the suction shut-off valve is greater than 10°F (-12.2°C) at the end of the freeze cycle Suction line temp. at the suction shut-off valve is less than 10°F (-12.2°C) at the end of the freeze cycle Suction line temp. at the suction shut-off valve is greater than 10°F (-12.2°C) at the end of the freeze cycle Final Analysis Enter total number of boxes checked in each column. Low On Charge -OrTXV Starving Refrigerant Overcharge -OrTXV Flooding Compressor Harvest Valve Leaking Part Number STH026 8/12 Part Number STH026 8/12 Freeze Cycle Refrigeration System Operational Analysis Tables Twin Expansion Valve – I1470C/I1870C/I2170C Models Operational Analysis Ice Production 1 2 3 4 Published 24-hour ice production __________ Calculated (actual) 24-hour ice production __________ NOTE: The ice machine is operating properly if the ice fill pattern is normal and ice production is within 10% of charted capacity. See “QuietQube® Models - Ice Production Check” on page 131 Installation and Water System All installation and water-related problems must be corrected before proceeding with chart. Ice Formation Pattern See “QuietQube® Models - Ice Formation Pattern” on page 135 Top Half _________________ or Left Bottom Half ______________ or Right Ice formation is extremely thin on outlet of one evaporator -orNo ice formation on top of one evaporator Ice formation is normal -orIce formation is extremely thin on outlet of one or both evaporators -orNo ice formation on one or both evaporators Ice formation is normal -orIce formation is extremely thin on the inlet of one evaporator -orNo ice formation on one evaporator Ice formation is normal -orNo ice formation on both evaporators 127 128 Twin Expansion Valve – I1470C/I1870C/I2170C Models Operational Analysis Safety Limits Refer to “Analyzing Safety Limits” page 113 to eliminate all non-refrigeration problems. Freeze Cycle Discharge Pressure ________ Part Number STH026 8/12 ________ ________ 1 minute Middle Freeze Cycle Suction Pressure 1 2 3 4 Stops on safety limit: 1 or 2 Stops on safety limit: 1 or 2 Stops on safety limit: 1 or 2 Stops on safety limit: 1 If discharge pressure is High or Low, refer to Freeze cycle high or low discharge pressure problem checklist page 139 & page 140 to eliminate problems and/or components not listed on this table before proceeding. End If suction pressure is High or Low, refer to Freeze cycle high or low suction pressure problem checklist page 143 to eliminate problems and/or components not listed on this table before proceeding. ________ ________ 1 minute ________ Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High or Normal Suction pressure is High Part Number STH026 8/12 Twin Expansion Valve – I1470C/I1870C/I2170C Models Operational Analysis 1 2 3 4 Harvest Valve Audible refrigerant flow through left or right valve in Freeze cycle No audible refrigerant flow through left or right valve in Freeze cycle No audible refrigerant flow through left or right valve in Freeze cycle No audible refrigerant flow through left or right valve in Freeze cycle Suction Line Temperature Attach a temperature probe on the suction line within 6 in. of the shut-off valve outlet. Record the low event at the end of the Freeze cycle. Suction line temperature at the suction shut-off valve is greater than 10°F (-12.2°C) at the end of the Freeze cycle Suction line temperature at the suction shut-off valve is greater than 10°F (-12.2°C) at the end of the Freeze cycle Suction line temperature at the suction shut-off valve is less than 10°F (-12.2°C) at the end of the Freeze cycle Suction line temperature at the suction shut-off valve is greater than 10°F (-12.2°C) at the end of the Freeze cycle Final Analysis Enter total number of boxes checked in each column. Harvest Valve Leaking Low on charge -orTXV starving Refrigerant Overcharge -orTXV flooding Compressor 129 QUIETQUBE® MODELS - FREEZE CYCLE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLE PROCEDURES The following is the procedures for completing each step of the Freeze Cycle Refrigeration System Operational Analysis Tables. Each procedure must be performed exactly for the table to work correctly. Before Beginning Service Ice machines may experience operational problems only during certain times of the day or night. A machine may function properly while it is being serviced, but malfunctions later. Information provided by the user can help the technician start in the right direction, and may be a determining factor in the final diagnosis. Ask these questions before beginning service: • When does the ice machine malfunction? (night, day, all the time, only during the Freeze cycle, etc.) • When do you notice low ice production? (one day a week, every day, on weekends, etc.) • Can you describe exactly what the ice machine seems to be doing? • Has anyone been working on the ice machine? • During “store shutdown,” is the circuit breaker, water supply or air temperature altered? • Is there any reason why incoming water pressure might rise or drop substantially? 130 Part Number STH026 8/12 QuietQube® Models - Ice Production Check The amount of ice a machine produces directly relates to the operating water and air temperatures. This means a condensing unit with a 70°F (21°C) outdoor ambient temperature and 50°F (10°C) water produces more ice than the same model condensing unit with a 90°F (32°C) outdoor ambient temperature and 70°F (21°C) water. 1. Determine the ice machine operating conditions: Air temp entering condenser:____° Air temp around ice machine:____° Water temp entering sump trough:____° 2. Refer to the appropriate 24-Hour Ice Production Chart (starting on page 211). Use the operating conditions determined in step 1 to find published 24-Hour Ice Production:_____ • Times are in minutes. Example: 1 min. 15 sec. converts to 1.25 min. (15 seconds ÷ 60 seconds = .25 minutes) • Weights are in pounds. Example: 2 lb. 6 oz. converts to 2.375 lb. (6 oz. ÷ 16 oz. = .375 lb.) 3. Perform an ice production check using the formula below. 1. _________ Freeze Time + _________ Harvest Time = _________ Total Cycle Time 2. 1440 _________ Minutes in 24 Hrs. ÷ _________ Total Cycle Time = _________ Cycles per Day 3. _________ Weight of One Harvest × _________ Cycles per Day = _________ Actual 24Hour Production Part Number STH026 8/12 131 Weighing the ice is the only 100% accurate check. However, if the ice pattern is normal and the 1/8 in. thickness is maintained, the ice slab weights listed with the 24-Hour Ice Production Charts may be used. 4. Compare the results of step 3 with step 2. Ice production checks that are within 10% of the chart are considered normal. If they match closely, determine if: • Another ice machine is required. • More storage capacity is required. • Relocating the existing equipment to lower the load conditions is required. Contact the local Manitowoc Distributor for information on available options and accessories. 132 Part Number STH026 8/12 QuietQube® Models - Installation/Visual Inspection Checklist Inadequate Clearances • Check all clearances on sides, back and top. See “Clearance Requirements” on page 31 Ice machine is not level • Level the ice machine Condenser is dirty • Clean the condenser Water filtration is plugged (if used) • Install a new water filter Water drains are not run separately and/or are not vented • Run and vent drains according to the Installation Manual Line set is improperly installed • Reinstall according to the Installation Manual Lineset is the incorrect size • Refer to Installation Use and Care Manual See “Lineset Applications” on page 35 Part Number STH026 8/12 133 QuietQube® Models - Water System Checklist A water-related problem often causes the same symptoms as a refrigeration system component malfunction. Water system problems must be identified and eliminated prior to replacing refrigeration components. Water area (evaporator) is dirty • Clean as needed Water inlet pressure not between 20 and 80 psig (1-5 Bar, 138-552 kPa). • Install water regulator or increase water pressure Incoming water temperature is not between 35°F (2°C) and 90°F (32°C) • If too hot, check the hot water line check valves in other store equipment Water filtration is plugged (if used) • Install a new water filter Water dump valve leaking during the Freeze cycle • Clean or replace dump valve as needed Vent tube is not installed on water outlet drain • See Installation Instructions Hoses, fittings, etc., are leaking water • Repair or replace as needed Water fill valve is stuck open or closed • Clean or replace as needed Water is leaking out of the sump trough area • Stop the water loss Uneven water flow across the evaporator • Clean the ice machine Plastic extrusions and gaskets are not secured to the evaporator • Remount/replace as needed 134 Part Number STH026 8/12 QuietQube® Models - Ice Formation Pattern Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction. However, when this analysis is used along with Manitowoc’s Freeze Cycle Refrigeration System Operational Analysis Tables, it can help diagnose an ice machine malfunction. Any number of problems can cause improper ice formation. Important Keep the water curtain, splash shields and ice dampers in place while checking the ice formation pattern to ensure no water is lost. 1. Normal Ice Formation Ice forms across the entire evaporator surface. At the beginning of the Freeze cycle, it may appear that more ice is forming on the inlet of the evaporator than on the outlet. At the end of the Freeze cycle, ice formation at the outlet will be close to, or just a bit thinner than, ice formation at the inlet. The dimples in the cubes at the outlet of the evaporator may be more pronounced than those on the inlet. This is normal. It is normal for ice thickness to vary up to 1/16" across the surface of the evaporator. The ice bridge thickness at the ice thickness control probe should be at least 1/8". The ice thickness probe must be set to maintain the ice bridge thickness at approximately 1/8 in. If ice forms uniformly across the evaporator surface, but does not reach 1/8 in. in the proper amount of time, this is still considered a normal ice fill pattern. Part Number STH026 8/12 135 2. Extremely Thin at Evaporator Outlet There is no ice, or a considerable lack of ice formation, at the outlet of the evaporator. Examples: No ice at all on the outlet half of the evaporator, but ice forms on the inlet half of the evaporator. Or, the ice at the outlet of the evaporator reaches 1/8 in. to initiate a harvest, but the inlet of the evaporator already has 1/2 in. to 1 in. of ice formation. 3. Extremely Thin at Evaporator Inlet There is no ice, or a considerable lack of ice formation at the inlet of the evaporator. Examples: The ice at the outlet of the evaporator reaches 1/8 in. to initiate a harvest, but there is no ice formation at all on the inlet of the evaporator. 4. No Ice Formation The ice machine operates for an extended period, but there is no ice formation at all on the evaporator. Evaporator Tubing Routing Routing of the tubing on the back of the evaporator determines the ice fill pattern failure mode. The evaporator outlet tubing does not exit directly at the top of the evaporator, but exits several inches below the top of the evaporator. Extremely Thin at the Evaporator Outlet will first be visible several inches below the top of the evaporator. Extremely Thin at Evaporator Inlet will first be visible at the bottom of the evaporator. Outlet ICE ICE Inlet Thin at Inlet 136 Thin at Outlet Part Number STH026 8/12 One Evaporator, Two TXV Models Tubing routing for one evaporator with two TXV’s is different. The evaporator has two inlets and outlets. Fill pattern varies depending on which circuit is affected, Extremely Thin at the Evaporator Outlet will first be visible either 1/4 or 3/4 of the way down the evaporator. Extremely Thin at the Evaporator Inlet will show at the bottom of the evaporator or 1/2 of the way down depending on the circuit affected. ICE Outlet Inlet ICE Thin at Inlet ICE Outlet Inlet ICE ICE Thin at Outlet Part Number STH026 8/12 137 Analyzing Discharge Pressure in the Freeze Cycle 1. Determine the ice machine operating conditions: Air temp. entering condenser______ Air temp. around ice machine______ Water temp. entering sump trough______ 2. Refer to Operating Pressure table (starting on page 211) for ice machine being checked. Use the operating conditions determined in step 1 to find the published normal discharge pressures. Freeze Cycle______ Harvest Cycle______ 3. Perform an actual discharge pressure check. Freeze Cycle psig (kPa) 1 Minute into the Freeze Cycle __________ Middle of Freeze Cycle __________ End of Freeze Cycle __________ 4. Compare the actual discharge pressure (step 3) with the published discharge pressure (step 2). The discharge pressure is normal when the actual pressure falls within the published pressure range for the ice machine’s operating conditions. It is normal for the discharge pressure to be higher at the beginning of the Freeze cycle (when load is greatest), then drop throughout the Freeze cycle. 138 Part Number STH026 8/12 FREEZE CYCLE DISCHARGE PRESSURE HIGH CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” (page 133) Air Condenser • Dirty condenser filter • Dirty condenser fins • High inlet air temperature • Condenser discharge air recirculation • Defective fan cycling control (page 180) • Defective fan motor • Defective head pressure control valve {Remote} Other • Overcharged • Non-condensable (air) in system • Wrong type of refrigerant • Non-Manitowoc components in system • High side refrigerant lines/component restricted Part Number STH026 8/12 139 QUIETQUBE® MODELS - FREEZE CYCLE DISCHARGE PRESSURE LOW CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” (page 133) Condenser • Defective head pressure control valve, won’t bypass (page 190) • Defective fan cycle control, stuck closed (page 180) Other • Undercharged • Wrong type of refrigerant • Non-Manitowoc components in system • Liquid line/component restricted 140 Part Number STH026 8/12 Analyzing Suction Pressure The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times. To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time. NOTE: Analyze discharge pressure before analyzing suction pressure. High or low discharge pressure may be causing high or low suction pressure. 1. Determine the ice machine operating conditions: Air temp. entering condenser______ Air temp. around ice machine______ Water temp. entering sump trough______ 2. Refer to Operating Pressure table (starting on page 211) for ice machine being checked. Use the operating conditions determined in step 1 to find the published normal discharge pressures. Freeze Cycle______ Harvest Cycle______ 3. Perform an actual suction pressure check. Freeze Cycle psig (kPa) 1 Minute into the Freeze Cycle __________ Middle of Freeze Cycle __________ End of Freeze Cycle __________ 4. Compare the actual suction pressure (step 3) with the published suction pressure (step 2). NOTE: The suction pressure is normal when the actual pressure falls within the published pressure range for the ice machine’s operating conditions. It is normal for the suction pressure to be higher at the beginning of the Freeze cycle (when load is greatest), then drop throughout the Freeze cycle. Part Number STH026 8/12 141 QuietQube® Models - Suction Pressure High Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” page 133 Discharge Pressure • Discharge pressure is too high and is affecting suction pressure – refer to “Freeze Cycle Discharge Pressure High Checklist” (page 139) Improper Refrigerant Charge • Overcharged (also see “Freeze Cycle Discharge Pressure High Checklist” page 139) • Wrong type of refrigerant • Non condensable in system Components • Harvest valve leaking • TXV flooding • Defective compressor Other • Non-Manitowoc components in system 142 Part Number STH026 8/12 QUIETQUBE® MODELS - SUCTION PRESSURE LOW CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” (page 133) Discharge Pressure • Discharge pressure is too low and is affecting low side – refer to “Freeze Cycle Discharge Pressure Low Checklist” (page 140) Improper Refrigerant Charge • Undercharged • Wrong type of refrigerant Other • Non-Manitowoc components in system • Improper water supply over evaporator – refer to “Water System Checklist” (page 134) • Restricted/plugged liquid line drier • Restricted/plugged tubing in suction side of refrigeration system • TXV starving • Liquid line solenoid valve closed Part Number STH026 8/12 143 QuietQube® Models - Harvest Valve Analysis Symptoms of a harvest valve remaining partially open during the freeze cycle can be similar to symptoms of either an expansion valve or compressor problem. The best way to diagnose a harvest valve is by using Manitowoc’s Ice Machine Freeze Cycle Refrigeration System Operational Analysis Table. Use the following procedures to determine if a harvest valve is remaining partially open during the freeze cycle. QUIETQUBE® HARVEST VALVE ANALYSIS The valve can fail in two positions: • Valve will not open in the Harvest cycle. • Valve remains open during the Freeze cycle. Valve will not open in the Harvest cycle Although the circuit board has initiated a Harvest cycle, suction and discharge pressures remain unchanged from the Freeze cycle. The ice machine will remain in the Harvest cycle for 3.5 minutes (7 minutes dual evaporators), then initiate a new Freeze cycle. Valve remains open in the Freeze cycle Symptoms of a harvest valve remaining partially open during the Freeze cycle can be similar to symptoms of an expansion valve or compressor problem. Symptoms are dependent on the amount of leakage in the Freeze cycle. A small amount of leakage will cause increased freeze times and an ice fill pattern that is normal. As the amount of leakage increases, the length of the Freeze cycle increases and the amount of ice on the bottom of the evaporator decreases. A small amount of leakage will cause an audible indication as the vapor passes through the valve. As the size of the leak increases, the audible indication becomes more apparent. 144 Part Number STH026 8/12 QuietQube® Models - Analyzing Freeze Cycle Suction Line Temperature Suction line temperature alone cannot diagnose an ice machine. However, comparing this temperature during the freeze cycle, along with using Manitowoc’s Symptom #2 - Refrigeration System Operational Analysis Table, can help diagnose an ice machine malfunction. The actual temperature of the suction line varies by model, and will change throughout the freeze cycle. This makes documenting the “normal” suction line temperature difficult. The key to the diagnosis is observing the compressor suction line temperature during the last three minutes of the freeze cycle. 1. Navigate to Service / Real Time Data / Time & Temp / T3 & T4 Thermistors (See page 84 Service Menu Navigation for details). 2. Monitor the suction line temperature during the last three minutes of the freeze cycle and record the low event. 3. Use this with other information gathered on the Refrigeration Component Analysis Chart to determine the ice machine malfunction. 4. Verify refrigerant amount is correct by weight when recovering refrigerant and replacing a TXV. Grossly overcharged QuietQube® ice machine in ambient temperatures below 70°F will have a suction line temperature below 10°F. Part Number STH026 8/12 145 QuietQube® Model Final Analysis The column with the highest number of Checkmarks identifies the refrigeration problem. COLUMN 1 - HARVEST VALVE LEAKING Replace the valve as required. COLUMN 2 - LOW CHARGE/TXV STARVING Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures. A low refrigerant charge normally affects both pressures. Verify the ice machine is not low on charge before replacing an expansion valve. 1. Do not add charge to QuietQube models. The symptoms of a QuietQube condensing unit low on charge will result in a safety limit #1 in cool ambient temperatures. Check the liquid line temperature at the ice machine. The liquid line will be hot with a normal or below normal head pressure in freeze when the ice machine is low on refrigerant. 2. Find the refrigerant leak. The ice machine must operate with the nameplate charge. If the leak cannot be found, proper refrigerant procedures must still be followed Change the liquid line drier. Then, evacuate and weigh in the proper charge. 3. Verify refrigerant charge by weight when recovering to prevent misdiagnosis of the expansion valve. 146 Part Number STH026 8/12 COLUMN 3 - TXV FLOODING OR REFRIGERANT OVERCHARGE A loose or improperly mounted expansion valve bulb causes the expansion valve to flood. Check bulb mounting, insulation, etc., before changing the valve. Verify refrigerant amount is correct by weighing recovered refrigerant before replacing a TXV. COLUMN 4 - COMPRESSOR Replace the compressor. To receive warranty credit, the compressor ports must be properly sealed by crimping and soldering them closed. Part Number STH026 8/12 147 SYMPTOM #3 HARVEST PROBLEMS Normal Ice Cube Melted Out Ice Cube Definition of a harvest problem; At the end of a 3.5 minute harvest cycle (7 minutes dual evaporators) the slab(s) of ice is still contacting the evaporator. The slab of ice may or may not be removable by hand. Harvest problems can be split into two categorizes. • • 148 Melted sheet of cubes at the end of the harvest cycle. Ice can be removed rather easily by hand. The back of the cubes are misshapen and melted. This indicates something is on the evaporator preventing the ice slab from releasing. Follow the appropriate flow chart (in Troubleshooting) to determine the cause of the problem. A manual cleaning procedure must always be performed when this problem is encountered. Normal sheet of cubes at the end of the harvest cycle. Ice is difficult to remove from the evaporator by hand. Once removed the back of the cubes are square and show no signs of melting. This indicates a refrigeration problem. The source of the problem could be in the freeze or harvest cycle. Use the appropriate flow chart (in Troubleshooting) to determine the cause of the problem. Part Number STH026 8/12 Part Number STH026 8/12 SYMPTOM #3 QUIETQUBE® MODELS WITH ICVD CONDENSING UNITS ICE MACHINE NOT HARVEST - FREEZE CYCLE NORMAL, CUBES ARE NOT Ice Machine WillWILL Not Harvest - Freeze Cycle Is Normal and Ice Cubes Are Not Melted After Afte MELTED Harvest START Is the Harvest Valve(s) Energized? NO Refer to Sequence of Operation & Wiring Diagram YES Note: All pressure readings are taken from the Liquid & Suction Shut-off Valves or access ports at the ice machine head section. Are the Harvest Pressures normal? YES NO Is the ice machine installed correctly? YES NO Correct the Installation 149 150 YES NO Is Head Pressure low & Suction Pressure low in harvest? Is Head Pressure high & Suction Pressure low in harvest? YES Replace Harvest Valve No; Harvest PSI Normal Part Number STH026 8/12 YES Feel temperature of Receiver after 30 seconds into harvest cycle Cold Feels Warm to Hot YES Not a refrigeration problem, Clean & Inspect Evaporator Part Number STH026 8/12 Cold Feel temperature of Liquid Line at rear of Head Section Feels Hot Backseat Liquid Line Shut Off Valve or Replace Cold Feel temperature of Liquid Line at Condensing Unit Feels Hot Look for Restriction, Correct Line Set Size, & Proper Insulation Cold Does the Condenser Fan Motor run below cut-out setpoint in harvest? NO YES Refer to Fan Cycling Control Diagnostics 151 152 NO Feel temperature of Discharge Line after 30 seconds into Harvest Cycle (refer to Harvest Headmaster Diagnostics) Headmaster is in 100% Bypass Part Number STH026 8/12 Refer to Symptom #2 Refrigeration Operational Analysis Table Headmaster is not in 100% Bypass IMPORTANT Weigh charge as you are recovering, if incorrect evacuate & recharge, if correct then proceed Refrigerant Charge is Incorrect Evacuate System, Recharge & perform Production Check Refrigerant Charge is Correct Change Headmaster Part Number STH026 8/12 SYMPTOM #4 QUIETQUBE® MODELS WITH ICVD CONDENSING UNITS Ice Machine Will Not Harvest - Freeze Cycle Is Normal and Ice Cubes Are Melted After Harvest START Back of cubes are melted at end of harvest cycle? NO YES NO Level Ice Machine YES NO Ice remains frozen to the evaporator at the end of the harvest cycle? Is Ice Machine level? Is water flow over the evaporator in the harvest cycle? YES Refer to Symptom #2 Freeze Cycle Operation Analysis Table NO YES Refer to Dump Valve Diagnostics 153 154 NO Is the evaporator dirty or damaged? (Dry evaporator first then check) YES NO Part Number STH026 8/12 Refer to Cleaning Procedures Refer to Symptom #2 Freeze Cycle Operational Analysis Table Component Check Procedures Electrical Components CONTROL BOARD, DISPLAY BOARD AND TOUCH PAD FUNCTION The control board, display board and touch pad provide user input and control the ice machine sequence of operation. NOTE: Anytime power is supplied to wires #55 & #56 on the control board, the “Display” and “Micro” lights should flash like a heartbeat. The two green lights are located on the top right corner of the control board. Display Diagnostics Symptom - Micro light flashes and display light is off. 1. Disconnect both ends of the communication cable running between the control board and the back of the display module and inspect for bent or damaged pins. Reconnect after inspection. 2. Reboot ice machine by disconnecting power for a minimum of 15 seconds, reapplying power and checking micro light for normal flashing. 3. Press the power button on the display and watch the green Display light on the control board. A. Display light flashes- Test run ice machine. B. Display light is off - Replace communication cable first as a test, then replace display/ touch pad assembly if required. Part Number STH026 8/12 155 Control Board Diagnostics 1. Micro light is not flashing a heartbeat. 2. Disconnect line voltage power supply to the ice machine and wait a minimum of 15 seconds, then reapply power. A. Micro light flashes - continue with step 3. B. Micro light is off - Replace control board. 3. Perform the following keystrokes on the display. • Press Menu, scroll down to Service and press right arrow • Scroll down to Diagnostics and press right arrow • Display reads Control Board, press right arrow • Display reads Self Check, press right arrow to start control board test The control board performs a self test. As the test progresses the display will show Checkmarks at the top left of the display screen. When the fifth Checkmark appears the display will show “Status Failed” or “Status Passed”. • Status passed -The control board is functioning normally, continue with touch pad diagnostics on next page. • Status failed - Replace control board. 156 Part Number STH026 8/12 Touch Pad Diagnostics Follow the control board diagnostics to “Status Passed”. Perform the following keystrokes on the display. • Display reads Status Passed, press the right arrow • Display reads Pass Yes, press the right arrow • Display reads Key Pad Test, press the right arrow 4. Test the functionality of all buttons on the touch pad. NOTE: Pushing the power button will start and stop the ice machine. Testing it last will allow the ice machine to continue running a freeze cycle. • As you press the buttons the first letter of the corresponding word will flash indicating the push button is operating correctly • Press the right arrow 5 times rapidly to exit. 5. Display reads Pass Yes and Pass No. • Press left arrow 4 times to exit to home screen. Part Number STH026 8/12 157 CONTROL BOARD RELAY TEST The control board can be set to energize all relays for 3.5 minutes. This allows testing to verify control board relays are closed and line voltage is available for ice machine components - Water pump, dump valve, water inlet valve, harvest valve(s), air compressor(s), contactor/compressor/fan motor - The fan cycle control must close to energize the fan motor. 1. Press power button to turn off ice machine. 2. Perform the following keystrokes on the display. • Press Menu, scroll down to Service and press the right arrow • Scroll down to Diagnostics, press the right arrow and select Diagnostics • Display reads Control Board, press right arrow • Scroll down to enbl relays and press right arrow to start control board test 3. The control board will energize all relays and the red light next to the relay. The red light indicates the relay coil is energized. 4. Test for line voltage at the individual components. A. Line voltage is present and the component is non functional - Replace component B. Voltage is not present at the component Proceed to step 5 5. Refer to wiring diagram and determine wire location on the 9 pin molex connector for the component you are testing. 6. Check for line voltage at the control board 9 pin molex connector. A. Line voltage at 9 pin connector - Repair wiring to component B. No power at 9 pin connector - Replace control board 158 Part Number STH026 8/12 PROGRAMMING A REPLACEMENT BOARD Indigo™ replacement control boards require the Model number to be entered to activate the appropriate look up tables for operation and diagnostic. This can be done two different ways, USB Setup or Manual Setup. USB Setup - Applicable when the control board is operational and has a mechanical issue such as a sticking relay. The asset data is transferred to the replacement control board from the faulty control board. Refer to page 100 “Exporting Data To A Flash Drive” before installing the replacement board. Manual Setup - Applicable when the control board is non-operational or data from the faulty board is suspect. Install replacement control board and reapply power. • G series (blue) control boards will go directly to the Replacement Control Board screen and pause for input - Select either “Manual” or “USB” setup option. • E series (beige) control boards require navigation to the Replacement Control Board (Repl Cntl Bd) screen. 1. Press the Menu button. 2. Press the Down arrow until Service is highlighted, then press the Checkmark. 3. Scroll down to Replacement Control Board and press the Checkmark. 4. Select “Manual Setup” and press the Checkmark. Verify the date correctly auto populates. • Yes - Go to step 5 • No - Press the right arrow to activate the cursor, then use up/down arrows to enter the correct date. Part Number STH026 8/12 159 5. Scroll down until brackets are in the space below “Input Model #”. Press the right arrow to activate the blinking cursor, then use the up/down arrows to select the first character in the model number. Use the right arrow to move to the next space. Add characters in this manner until the model number is complete. The model must include the dash and the last three numbers to indicate the electrical requirements ( example -261). Press the right arrow until the cursor disappears. 6. Scroll down until brackets are in the space below “Input Serial#”. Press the right arrow to activate the blinking cursor, then use the up/down arrows to select the first character in the serial number. Use the right arrow to move to the next space. Add characters in this manner until the serial number is complete. Press the right arrow until the cursor disappears. 7. Scroll down and select exit, then press checkmark. 8. Reboot ice machine by disconnecting power for a minimum of 15 seconds, then reapply power. 160 Part Number STH026 8/12 MAIN FUSE FUNCTION The control board fuse stops ice machine operation if electrical components fail, causing high amp draw. SPECIFICATIONS The main fuse is 250 Volt, 8 amp. ! Warning High (line) voltage is applied to the control board (terminals #55 and #56) at all times. Removing the control board fuse or pressing the On/Off button will not remove the power supplied to the control board. CHECK PROCEDURE 1. If the bin switch light is on with the water curtain/ ice dampers closed, the fuse is good. ! Warning Disconnect electrical power to the entire ice machine before proceeding. 2. Remove the fuse. Check for continuity across the fuse with an ohmmeter. Reading Result Open (OL) Replace fuse Closed (O) Fuse is good Part Number STH026 8/12 161 BIN SWITCH FUNCTION Movement of the water curtain/ice dampers control bin switch operation. The bin switch has two main functions: 1. Terminating the Harvest cycle and returning the ice machine to the Freeze cycle. This occurs when the bin switch is opened and closed again within 30 seconds during the Harvest cycle. 2. Automatic ice machine shut-off. If the storage bin is full at the end of a Harvest cycle, the sheet of cubes fails to clear the water curtain/ice dampers and holds it open. After the water curtain/ice dampers are held open for 30 seconds, the ice machine shuts off. The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain/ice dampers. As the water curtain/ice dampers swing back to the operating position, the bin switch closes and the ice machine restarts, provide the 3-minute delay has expired. Important The water curtain/ice dampers must be ON (bin switch closed) to start ice making. SPECIFICATIONS The bin switch is a magnetically operated reed switch. The magnet is attached to the lower right corner of the water curtain and both ends of ice dampers. The bin switch is connected to a varying D.C. voltage circuit. (Voltage does not remain constant.) NOTE: Because of a wide variation in D.C. voltage, it is not recommended that a voltmeter be used to check bin switch operation. 162 Part Number STH026 8/12 Diagnostics SYMPTOMS Bin Switch Fails Open G Model control boards or E Model control boards with firmware version Rev.2.047 or higher. • The ice machine will not start an ice making cycle and the display indicates “Full Bin”. • The ice machine displays “Full Bin Remove Ice” in the clean cycle. E Control Boards with firmware versions prior to Rev.2.047 • The ice machine will not start an ice making cycle and the display indicates “Curtain Open”. • The ice machine will run in the clean cycle. Bin Switch Fails Closed • When running a “Long Harvest” alert is displayed and safety limit 2 indicated. • May be off on a safety limit 2. • The harvest cycle continues after ice opens and closes the ice damper (harvest cycle is 3.5 minutes). Part Number STH026 8/12 163 DIAGNOSTICS • • • • 1. Verify bin switch, curtain/damper and curtain/ damper magnet are in place. Press the Menu button. Scroll down to Service and press right arrow. Scroll down to Diagnostics and press right arrow Scroll down to Inputs and press right arrow to display curtain switch readings (Curt SW1, Curt SW2, etc). 2. Open and close the ice damper(s) repeatedly while observing the display and control board lights. A. Curtain switch cycles open/closed and control board light energizes/de-energizes Bin switch is operating normally B. Curtain switch remains closed and control board light remains on - Go to step 3 C. Curtain switch remains open and control board light remains off - Go to step 3 3. Disconnect bin switch wire from control board. 4. Jumper control board bin switch wire to ground, press the power button and observe the display and control board lights. A. Curtain switch closes, control board light energizes and ice machine starts - Replace bin switch B. Curtain switch remains open and control board light is off - Verify procedure was correctly followed - Replace control board. 164 Part Number STH026 8/12 WATER LEVEL CONTROL CIRCUITRY FUNCTION The water level probe controls the water level by sensing whether water is or is not contacting the water level probe. The water level probe has three sensing probes. Two probes are equal in length and are used to measures conductivity for diagnostics, ice clarity and water miser options. Factory default settings measure resistance from both long probes to the short probe. SPECIFICATIONS Freeze Cycle Water Level Setting During the Freeze cycle, the water level probe is set to maintain the proper water level above the water pump housing. The water level is not adjustable. If the water level is incorrect, check the water level probe position. Reposition or clean the probe as necessary. Water Inlet Valve Safety Shut-Off In the event of a water level probe failure, this feature limits the water inlet valve to 12.5 minutes. Regardless of the water level probe input, the control board automatically shuts off the water inlet valve if it remains on for 12.5 continuous minutes (30 seconds in prechill and two 6 minute periods in the freeze cycle). Part Number STH026 8/12 165 Prechill & Freeze Cycle Operation The water inlet valve energizes and de-energizes in conjunction with the water level probe located in the water trough. • The water inlet valve is ON when there is no water in contact with the water level probes. • The water inlet valve turns OFF after water contacts the water level probes for 3 continuous seconds. • The water inlet valve can cycle ON and OFF once in the prechill and up to two times in the freeze cycle. • Maximum fill time is 12.5 minutes for single evaporator machines, 16.5 minutes for dual evaporator machines. The water inlet valve energizes in the Prechill cycle and will de-energize if water touches the high level probe (in most instances the water trough can’t fill in the prechill cycle and the water inlet valve will remain energized into the freeze cycle). The water inlet valve will remain energized until water contacts the high water probe. The water inlet valve will cycle ON, and then OFF one more time to refill the water trough. The water inlet valve is now OFF for the duration of the freeze cycle. 166 Part Number STH026 8/12 Diagnostics SYMPTOMS • Water trough overfills • Water trough will not fill WATER TROUGH OVERFILLING DURING THE FREEZE CYCLE Step 1 Press the power button and turn off the ice machine. Step 2 If water continues to flow with the ice machine off, disconnect power. If water continues to flow with power disconnected verify water pressure is below 80 psig before replacing the water inlet valve. If the water stops continue with step 2. Step 3 Check water level probe mounting and verify secure wiring connections at the probe and control board. Step 4 Scroll to Service/Diagnostics/Inputs and press down arrow until Wtr Low and Wtr High are displayed. • No is displayed on both Wtr low and Wtr high - The control board is not receiving a sensing water signal - Go to next step. • Yes is displayed - The control board is receiving a sensing water signal from the low and high probes - Replace the control board. Part Number STH026 8/12 167 Step 5 Disconnect the water level probe wiring harness from the control board and ohm harness and water level probe. Normal readings will show no resistance. Black White Red Short Probe Ohm water Level Probe and Wiring Harness 168 Part Number STH026 8/12 Step 6 When all ohm tests are normal, replace the control board. When any measurement fails, disconnect the wiring harness from the water level probe and ohm the water level probe with the wiring harness removed from the circuit. Results will determine whether the wiring harness or probe will need replacement. Empty Terminal Short Probe Ohm Water Level Probe Part Number STH026 8/12 169 WATER TROUGH WILL NOT FILL Step 1 Verify water is supplied to the ice machine. Step 2 Scroll to Service/Diagnostics/Inputs and press down arrow until Wtr Low and Wtr High are displayed. A. Yes is displayed - Control board is receiving a sensing water signal. Proceed to step 3. B. No is displayed - Control board is not receiving a sensing water signal. Proceed to Control Board Diagnostics page 156. Step 3 Disconnect water level probe, observe LCD display text. A. No is displayed - Clean the water level probe and test interconnecting wiring. B. Yes is displayed - Refer to Control Board Diagnostics page 156 Step 4 Ohm probe - Refer to previous page for procedure. WATER LEVEL PROBE CIRCUIT CHECK AT CONTROL BOARD Wait until prechill cycle starts, then jumper water level probe connections (2 & 3) on the control board. A. Wtr High displays yes and the water stops. Repair wire or replace water level probe. B. Wtr High displays No and the water continues to flow. Replace control board. 170 Part Number STH026 8/12 ICE THICKNESS PROBE FUNCTION The ice thickness probe senses ice on the evaporator and signals the control board to start a harvest cycle. After ice forms on the evaporator, the ice will contact the ice thickness probe and a harvest cycle is initiated. SPECIFICATIONS Freeze Time Lock-In Feature The ice machine control system incorporates a freeze time lock-in feature. This prevents the ice machine from short cycling in and out of harvest. The control board locks the ice machine in the freeze cycle and a harvest cycle can not start for six minutes. Maximum Freeze Time The control system includes a built-in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle. Maximum Temperature Maximum temperature for the ice thickness probe is 120 degrees F (49 degree’s C). Do not clean probe in a dishwasher or expose to temperatures above the maximum. Part Number STH026 8/12 171 Ice Thickness Check The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8 in. (32 mm). NOTE: Make sure the water curtain/splash shields are in place when performing this check. It prevents water from splashing out of the water trough. Remove the curtain/splash shield to make an adjustment, then replace immediately after the adjustment is made. 1. Inspect the bridge connecting the cubes. It should be about 1/8 in. (32 mm) thick. 2. If adjustment is necessary, turn the ice thickness probe adjustment screw clockwise to increase bridge thickness or counterclockwise to decrease bridge thickness. Set a 9/32” gap between the ice thickness probe and evaporator as a starting point. Then adjust to achieve 1/8” ice thickness. 3. Make sure the ice thickness probe wire and the bracket do not restrict movement of the probe ADJUSTING SCREW 1/8” ICE BRIDGE THICKNESS PLACE 9/32” (7mm) DRILL BIT HERE TO SET INITIAL GAP ICE THICKNESS ADJUSTMENT 172 Part Number STH026 8/12 Diagnostics ICE MACHINE CYCLES INTO HARVEST BEFORE ICE CONTACTS THE ICE THICKNESS PROBE Premature harvest symptoms • Low ice production • Thin ice in bin • Freeze cycles are faster than published cycle times 1. Turn off power and inspect ice thickness probe for physical damage. Look for bulging, cracks around the nipple or deformed pivot pins. 2. Verify ice thickness probe gap is approximately 9/32” (7 mm) 3. Make sure the ice thickness probe wire doesn’t restrict movement. 4. Perform Ice Thickness Probe tap test: • Press the menu button, scroll down to Service, press the right arrow, scroll down to Real Time Data, press right arrow - With the brackets around Time & Temp press the right arrow - Scroll down until 100Hz &120Hz are displayed. Slowly increasing and decreasing numbers typically in the 200Hz to 300Hz range will display to the right of 100Hz &120Hz. • Lift the Ice Thickness Probe and continuously tap the nipple while watching the numbers to the right of the 100Hz and 120Hz. There is a slight delay while tapping. Pass Numbers increasing into the thousands indicates a properly working ice thickness probe and control board. Fail Numbers do not move or do not increase into the thousands - Ohm the ice thickness probe. Part Number STH026 8/12 173 5. Ohm Ice Thickness Probe NOTE: Verify meter leads are properly connected to VOM with the red meter lead connected to positive & the black meter lead connected to negative • Disconnect Ice Thickness Probe from control board • Connect red meter lead to the red wire and the black meter lead to the black wire - Normal readings = 1.4 to 2.5 KΩ's. • Reverse leads - Connect black meter lead to the red wire, red meter lead to the black wire - Normal readings = 1.2 to 1.5 KΩ's. • Pass Ohm values are within range - Check control board voltage at the ice thickness probe connection. Fail Replace ice thickness probe. 6. Check control board voltage Set VOM to DC voltage scale - Check voltage across the top and bottom pin - Normal readings = 3.25 to 3.35 VDC. Pass Control board voltage is normal Fail Replace control board 174 Part Number STH026 8/12 ICE MACHINE DOES NOT CYCLE INTO HARVEST Will not harvest symptoms • Low ice production • Thick ice in bin • Large sheet of ice on evaporator • Harvest cycle doesn’t start • Freeze cycles are longer than published cycle times If ice is on the evaporator initiate a manual harvest cycle by performing the following keystrokes. • Press Menu • Scroll down to Service and press right arrow • Scroll down to Manual Harvest and press right arrow - A new freeze cycle will start after the manual harvest cycle is complete. NOTE: Ice must be off the evaporator before starting the procedure. 1. Disconnect the ice thickness probe from the control board, then reboot the control board by disconnecting and reconnecting line voltage to the ice machine. 2. Wait six minutes into the freeze cycle (timing starts when the water pump energizes). • Ice Machine cycles into harvest normally - Perform steps 1 & 2 on page 173 to test ice thickness probe and control board. • Ice machine will not cycle into harvest - Perform steps 1 through 4 on page 173 to test ice thickness probe and control board. Part Number STH026 8/12 175 HIGH PRESSURE CUTOUT (HPCO) CONTROL FUNCTION Stops the ice machine if subjected to excessive highside pressure. The HPCO control is normally closed, and opens on a rise in discharge pressure. SPECIFICATIONS. Specifications Cut-Out Cut-In 450 psig ±7 300 psig ±10 (3102 kPa ±48 31 bar ±.48) (2068 kPa 20.68 bar) Automatic Reset SYMPTOM Opening the HPCO will cause the control board to initiate a 60 minute delay. The display counts down from 60 minutes to 0 minutes, at which point the ice machine attempts a restart. If the HPCO is closed the ice machine will continue to run. If the HPCO remains open after the 60 minute delay or reopens when the compressor starts, the ice machine will start another 60 minute delay period. 1. Machine is off and the display indicates “Delay XX min, HPCO Active” 2. Machine is running and the display has an alert triangle - Press left arrow to display “HPC Fault”. 176 Part Number STH026 8/12 CHECK PROCEDURE Symptom #1 Machine is off and the display indicates “Delay xx min, HPCO Active”. 1. Cycle ice machine with the on/off button.The ice machine will go to an initial start sequence if the HPCO is closed. If the HPCO is open, another 60 minute delay period starts. • Ice Machine starts - Run the system to see if the control trips at the rated pressure. If HPCO opens at a pressure significantly lower or higher than the control setting of 450 psig replace the HPCO. If the control opens at the correct pressure find the root cause - Fan motor, dirty condenser, refrigeration system issue, etc. • Ice Machine Does Not Start - Continue with the next step. 2. Leave all wiring connectors attached and perform testing within the 60 minute time delay period. Check for 24 volts at terminals V & C (interconnecting wiring connections) on the ice machine control board. A. 24 volts - Proceed with next step B. 0 Volts - Restore line voltage to condensing unit, or repair interconnecting wiring, or replace transformer in condensing unit. 3. Check for 24 volts at terminals C & HPC1. A. 24 volts - Proceed with next step. B. 0 volts - HPCO switch is open. Verify pressure - Below cut-in replace HPCO Above cut-in find root cause problem. 4. Check for 24 volts at terminals C & HPC2. A. 24 volts - Faulty relay on control board Replace control board. B. 0 volts - HPCO switch is open. Verify pressure - Below cut-in, replace HPCO Above cut-in, find root cause problem. Part Number STH026 8/12 177 Symptom #2 Machine is running and the display has a flashing alert triangle and indicates “HPC Fault” after the left arrow is pressed 1. Navigate to the event log on the Service menu. Scroll down to HPC Fault EO5. Open the event and view when and how often HPCO Fault has occurred. 2. If this is a one time event it may be intermittent and caused by conditions around the unit changing. For example: High ambient temperature, water turned off to condenser (water cooled unit) etc. 3. Run the system to see if the control trips at the rated pressure. If HPCO opens at a pressure significantly lower than the control setting of 450 psig replace the HPCO. 4. If the control opens at the correct pressure (+-10 lbs) find the root cause - Fan motor, dirty condenser, refrigeration system issue, etc. 178 Part Number STH026 8/12 LOW PRESSURE CUTOUT (LPCO) CONTROL FUNCTION Signals the control board to energize and de-energize the contactor when suction pressure rises above or falls below setpoint. The LPCO control is closed at pressures above setpoint and opens at pressures below setpoint. Specifications Cut-Out Cut-In 12 psig ±3 35 psig ±5 CHECK PROCEDURE • • • • 1. Navigate to LPCO input on display Press the Menu button. Scroll down to Service and press right arrow. Scroll down to Diagnostics and press right arrow Scroll down to Inputs and press right arrow to display LPCO reading 2. LPCO display indicates A. Open = Replace Switch B. Closed = Switch OK 3. Connect manifold gauges and verify refrigerant pressure exceeds LPCO cut-in. If pressure exceeds cut-in and the contacts are open, replace the LPCO. Part Number STH026 8/12 179 FAN CYCLE CONTROL FUNCTION Cycles the fan motor on and off to maintain proper operating discharge pressure. The fan cycle control closes on an increase, and opens on a decrease in discharge pressure. SPECIFICATIONS Specifications Cut-In (Close) Cut-Out (Open) 250 ±5 (1723 kPa ±.34) (17.23 bar ±.34) 200 ±5 (1517 kPa ±.34) (15.17 bar ±.34) Model ICVD0695 ICVD0895 ICVD1095 ICVD1195 ICVD1295 ICVD1495 ICVD1895 ICVD2095 CHECK PROCEDURE 1. Verify fan motor windings are not open or grounded, and fan spins freely. 2. Connect manifold gauges to ice machine. 3. Hook voltmeter in parallel across the fan cycle control, leaving wires attached. 4. Refer to chart below. FCC Setpoint: Reading Should Be: Above Cut-In Below Cut-Out 0 Volts Line Voltage 180 Fan Should Be: Running Off Part Number STH026 8/12 THERMISTORS FUNCTION Thermistor resistance values change with temperature. The value supplied to the control board is used to identify temperature at the thermistor location. SPECIFICATIONS: Temperature of Thermistor Resistance °C °F -30° - -20° -22° - -4° K Ohms (x 1000) 820.85 - 466.35 -20° - -10° -4° - 14° 466.35 - 269.05 -10° - 0° 14° - 32° 269.05 - 160.70 0° - 10° 32° - 50° 160.70 - 98.930 10° - 20° 50° - 68° 98.930 - 62.015 20° - 30° 68° - 86° 62.015 - 39.695 30° - 40° 86° - 104° 39.695 - 25.070 40° - 50° 104° - 122° 25.070 - 17.481 50° - 60° 122° - 140° 17.481 - 11.860 60° - 70° 140° - 158° 11.860 - 8.1900 70° - 80° 158° - 176° 8.1900 - 5.7530 80° - 90° 176° - 194° 5.7530 - 4.1015 90° - 100° 194° - 212° 4.1015 - 2.9735 100° - 110° 212° -230° 2.9735 - 2.1885 110° - 120° 230° - 248° 2.1885 - 1.6290 120° - 130° 248° - 266° 1.6290 - 1.2245 130° - 140° 266° - 284° 1.2245 - 0.9319 140° - 150° 284° - 302° 0.9319 - 0.7183 150° - 160° 302° - 320° 0.7183 - 0.5624 160° - 170° 320° - 338° 0.5624 - 0.4448 170° - 180° 338° - 356° 0.4448 - 0.3530 180° - 190° 356° - 374° 0.3530 - 0.2831 190° - 200° 374° - 392° 0.2831 - 0.2273 Part Number STH026 8/12 181 182 QuietQube 1 Evaporator with 2 Circuits or 2 Evaporators RCU Air-Cooled T4 T4 QuietQube 1 Evaporator with 1 Circuit RCU Air-Cooled T3 T4 30" & 48" 1 Evaporator with 2 Circuits RCU Air-Cooled T4 T3 30" 1 Evaporator with 1 Circuit RCU Air-Cooled T4 T4 T3 T3 T3 T3 T2 T2 T2 T2 T1 T1 T1 T1 T1 T1 T2 T2 Evaporator Evaporator Evaporator Out Compressor Condenser Receiver Receiver In Out for 1st for 2nd circuit Discharge Liquid Line Inlet Outlet or 2nd circuit Evaporator 30" & 48" 1 Evaporator with 2 Circuits IMH Air-Cooled & Water-Cooled 22" & 30" 1 Evaporator with 1 Circuit IMH Air-Cooled & Water-Cooled Ice Machine Description TEMPERATURE SENSOR LOCATION Thermistor Matrix Part Number STH026 8/12 SYMPTOM Alert icon on the display is flashing and the alert indicates a T1, T2, T3, or T4 Fault. CHECK PROCEDURE • • • • Press the Menu button. Scroll down to Service and press right arrow. Scroll down to Diagnostics and press right arrow Scroll down to Temp Sensors and press right arrow to display thermistor temperature readings. NOTE: An open thermistor will display -22°F (-30°C) and a shorted thermistor displays 475°F (246°C). Thermistor Test 1. Disconnect thermistor from control board and measure resistance. 2. Measure temperature at the thermistor. 3. Compare measured resistance/temperature readings to resistance/temperature relationship chart. A. Within 10% of the published resistance value - Thermistor is good B. Not within 10% of the published resistance value - Thermistor is defective. Control Board Test 1. Disconnect thermistor from control board - The display temperature reading, dropping to -22°F (-30°C) indicates the control board is good. 2. Short thermistor pins - The display temperature reading, climbing to 475°F (246°C) indicates the control board is good. Part Number STH026 8/12 183 HARVEST ASSIST AIR PUMP FUNCTION The air pump helps break the vacuum between the sheet of ice and the evaporator which results in shorter harvest cycles. SPECIFICATIONS 115 Volt or 230 Volt - matches the ice machine voltage. CHECK PROCEDURE 1. The air pump is wired in parallel with the harvest valve - Verify the ice machine is in the harvest cycle and the harvest valve is energized. 2. If there is voltage at the air pump connector, use a volt ohm meter to verify there is no continuity through the motor windings then replace motor. 184 Part Number STH026 8/12 COMPRESSOR ELECTRICAL DIAGNOSTICS The compressor does not start or will trip repeatedly on overload. Check Resistance (Ohm) Values NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter. Perform the resistance test after the compressor cools. The compressor dome should be cool enough to touch (below 120°F/49°C) to assure that the overload is closed and the resistance readings will be accurate. SINGLE PHASE COMPRESSORS 1. Disconnect power then remove the wires from the compressor terminals. 2. The resistance values between C and S and between C and R, when added together, should equal the resistance value between S and R. 3. If the overload is open, there will be a resistance reading between S and R, and open readings between C and S and between C and R. Allow the compressor to cool, then check the readings again. THREE PHASE COMPRESSORS 1. Disconnect power and remove the wires from the compressor terminals. 2. The resistance values between L1 and L2, between L2 and L3, and between L3 and L1 should all be equal. 3. If the overload is open, there will be open readings between L1 and L2, between L2 and L3, and between L3 and L1. Allow the compressor to cool, then check the readings again. Part Number STH026 8/12 185 CHECK MOTOR WINDINGS TO GROUND Check continuity between all three terminals and the compressor shell or copper refrigeration line. Scrape metal surface to get good contact. If continuity is present, the compressor windings are grounded and the compressor should be replaced. COMPRESSOR DRAWING LOCKED ROTOR To determine if the compressor is seized, check the amp draw while the compressor is trying to start. The two likely causes of this are a defective starting component or a mechanically seized compressor. To determine which you have: 1. Install high and low side gauges. 2. Try to start the compressor. 3. Watch the pressures closely. A. If the pressures do not move, the compressor is seized. Replace the compressor. B. If the pressures move, the compressor is turning slowly and is not seized. Check the capacitors and relay. COMPRESSOR DRAWING HIGH AMPS The continuous amperage draw on start-up should not be near the maximum fuse size indicated on the serial tag. 186 Part Number STH026 8/12 DIAGNOSING START COMPONENTS If the compressor attempts to start, or hums and trips the overload protector, check the start components before replacing the compressor. Capacitor Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane. Do not assume a capacitor is good if no visual evidence is present. A good test is to install a known good substitute capacitor. Use a capacitor tester when checking a suspect capacitor. Clip the bleed resistor off the capacitor terminals before testing. Relay The relay has a set of contacts that connect and disconnect the start capacitor from the compressor start winding. The contacts on the relay are normally closed (start capacitor in series with the start winding). The relay senses the voltage generated by the start winding and opens the contacts as the compressor motor starts. The contacts remain open until the compressor is de-energized. RELAY OPERATION CHECK 1. Disconnect wires from relay terminals. 2. Verify the contacts are closed. Measure the resistance between terminals 1 and 2. No continuity indicates open contacts. Replace the relay. 3. Check the relay coil. Measure the resistance between terminals 2 and 5. No resistance indicates an open coil. Replace the relay. Part Number STH026 8/12 187 PTCR The PTCR allows current to flow through the start winding at compressor startup. Current flow heats the ceramic discs in the PTCR. The electrical resistance increases with temperature and stops all except a trickle of current flow through the start winding. The small flow of current keeps the PTCR hot (260°F/ 127°C) and the start winding out of the circuit. The PTCR must be cooled before attempting to start the compressor, otherwise the PTCR will heat up too quickly and stop current flow through the start winding before the compressor motor reaches full speed. ! Warning Disconnect electrical power to the entire ice machine at the building electrical disconnect box before proceeding. NOTE: If a PTCR is dropped internal damage can occur to the ceramic PTCR discs. The ceramic disc can chip and cause arcing which leads to PTCR failure. Since there is no way to open the PTCR in order to determine if the ceramic disc is chipped or not, it must be discarded when dropped. 188 Part Number STH026 8/12 PTCR Operation Check 1. Visually inspect the PTCR. Check for signs of physical damage. NOTE: The PTCR case temperature may reach 210°F (100°C) while the compressor is running. This is normal. Do not change a PTCR just because it is hot. 2. Wait at least 10 minutes for the PTCR to cool to room temperature. 3. Remove the PTCR from the ice machine. 4. Measure the resistance of the PTCR as shown. The resistance reading must be between: • Two Terminal PTCR Black = 24.5 to 45.5 ohms • Two Terminal PTCR Blue = 21 to 39 ohms • Three Terminal PTCR Tan = 10.5 to 19.5 ohms. Measure Resistance At Ends Two Terminal PTCR Measure Resistance @ Center and End Leave Jumper Wire Attached Three Terminal PTCR Part Number STH026 8/12 189 Refrigeration Components HEAD PRESSURE CONTROL VALVE Manitowoc remote systems require head pressure control valves with special settings. Replace defective head pressure control valves only with “original” Manitowoc replacement parts. Refrigerant Charge Verification The correct amount of refrigerant (name plate charge) is required to operate correctly at all ambient conditions. An ice machine with an overcharge or undercharge of refrigerant may function properly at higher ambient temperatures and fails at lower ambient temperatures. Symptoms of incorrect refrigerant amount are: • Works during the day and malfunctions at night, and/or fails whenever the outdoor temperature drops. • A Safety limit is stored in control board memory. Refrigerant loss and ambient temperature are directly related to each other. As the ambient temperature drops, more refrigerant is stored in the condenser. When the refrigerant charge and ambient temperature create an undercharge of refrigerant in the freeze cycle, the receiver dip tube will lose it’s liquid seal. Without liquid refrigerant to the TXV, the ice machine fails to make a full sheet of ice in 60 minutes and a safety limit #1 results. NOTE: When a head pressure control valve is being replaced or refrigerant charge is suspected, verify the refrigerant charge is correct by recovering the refrigerant, weighing and comparing to the nameplate amount. Refer to Refrigerant Recovery/Evacuation” for recovery procedures. 190 Part Number STH026 8/12 Freeze Cycle Operation All Models The R404A head pressure control valve is non adjustable. At ambient temperatures of approximately 70°F (21°C) or above, refrigerant flows through the valve from the condenser to the receiver inlet. At temperatures below this (or at higher temperatures if it is raining), the head pressure control dome’s nitrogen charge closes the condenser port and opens the bypass port from the compressor discharge line. In this modulating mode, the valve maintains minimum head pressure by building up liquid in the condenser and bypassing discharge gas directly to the receiver. Harvest Cycle Operation During the Harvest cycle, the harvest valve opens and allows refrigerant from the top of the receiver tank to enter the evaporator. The refrigerants change of state (from vapor to liquid) releases the heat necessary for the Harvest cycle. Opening the harvest valve causes a drop in discharge pressure. The discharge pressure will drop below the condenser fan cycling control setpoint and the condenser fan motor cycles off (at ambient temperatures above 110°F (43°C) the condenser fan motor remains energized). The warm discharge gas adds heat to the receiver in the harvest cycle. Without this additional heat the head pressure would continue to drop as liquid refrigerant boils off in the receiver. Example: A service technician removes refrigerant vapor from a cylinder by boiling off the liquid refrigerant. A refrigeration effect is created as the refrigerant changes state from a liquid to a vapor. The cylinder cools and the refrigerant pressure drops. To maximize flow and maintain pressure the technician places the cylinder in warm water. Part Number STH026 8/12 191 Diagnostics FREEZE CYCLE - QUIETQUBE® REMOTE CONDENSING UNIT 1. Determine if the coil is clean. 2. Determine the air temperature entering the condenser. 3. Determine if the head pressure is high or low in relationship to the outside temperature. (Refer to the proper “Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts” page 211). 4. Determine the temperature of the liquid line entering the receiver by feeling it. This line is normally warm; “body temperature.” 5. Using the information gathered, refer to the chart. NOTE: A head pressure control valve that will not bypass, will function properly with condenser air temperatures of approximately 70°F (21°C) or above. When the temperature drops below 70°F (21°C), the head pressure control valve fails to bypass and the ice machine malfunctions. Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle. Condition Probable Cause Corrective Measure Discharge Pressure - High Liquid Line Temperature Hot Valve stuck in bypass Replace valve Discharge Pressure - Low Liquid Line Temperature Cold Valve not bypassing Replace valve Discharge Pressure - Low Liquid Line Temperature Hot Ice Machine Low on Charge Refrigerant Charge Verification 192 Part Number STH026 8/12 Harvest Cycle QUIETQUBE ® REMOTE CONDENSING UNIT QuietQube® ice machines may fail in the harvest cycle when the refrigerant charge and ambient temperature create a marginal undercharge of refrigerant. The ice machine may be able to make a full sheet of ice, but fails in the harvest cycle when the receiver runs out of liquid refrigerant. A safety limit #2 will result when the ice machine is unable to harvest. Undercharge Symptoms • Safety limit #1 or Safety limit #2 in control board memory, a flashing triangle alert and after pressing left arrow Long Freeze or Long Harvest is displayed. • Harvest cycle suction pressure is low. • Harvest cycle discharge pressure is low. • Liquid line entering receiver feels warm to hot in the freeze cycle. Overcharge Symptoms • Safety limit #2 in control board memory, a flashing triangle alert and after pressing left arrow Long Harvest is displayed. • Harvest cycle discharge pressure is normal. • Freeze cycle time, suction and discharge pressure are normal and the ice machine will not harvest. The sheet of ice cubes show little or no sign of melting when removed from the evaporator after the harvest cycle has been completed. (If the cubes are melted you have a release problem, clean the ice machine). Part Number STH026 8/12 193 HARVEST CYCLE DIAGNOSTICS QUIETQUBE ® REMOTE CONDENSING UNIT The headmaster control valve diverts the compressor discharge gas to the ice machine receiver in the harvest cycle. All refrigerant flow through the condenser in the harvest cycle stops. Symptoms of a headmaster valve that will not seat 100% closed (completely bypass the condenser) in the harvest cycle are: • Freeze cycle suction and discharge pressure are normal. • The control board indicates safety limit #2 a flashing triangle alert and after pressing left arrow Long Harvest is displayed. The failure seems to be temperature related. Example: The ice machine may function correctly at temperatures above 32°F but fails at temperatures below 32°F. • Harvest cycle suction pressure is low. • Harvest cycle discharge pressure is normal or slightly low. Procedure 1. Freeze cycle operation must be normal before diagnosing the headmaster in the harvest cycle. (Refer to Cycle Times/24 hr Ice Production/ Refrigerant Pressure Chart) 2. Allow the ice machine to run a normal freeze cycle (do not initiate an early harvest cycle). 3. At the start of the harvest cycle feel the compressor discharge line and the liquid line to the ice machine receiver at the headmaster valve. The temperature of both lines will be highest at the beginning of the harvest cycle and then decrease. Compare the lines 30 seconds into the harvest cycle and then refer to Harvest Cycle Headmaster Control Valve Failure List page 190. 194 Part Number STH026 8/12 Step 3 Details Grasp Here with Hands to Compare Temperatures rig No Flow R ef Flow t n era LIQUID LINE FROM CONDENSER HARVEST CYCLE HEADMASTER CONTROL VALVE FAILURE LIST Temperature of the compressor discharge line and liquid line to the ice machine receiver feel the same 30 seconds into the harvest cycle. • The headmaster is functioning correctly. The compressor discharge line is noticeably warmer than the liquid line to the ice machine receiver. • Headmaster valve is not bypassing 100%. Replace headmaster valve. Part Number STH026 8/12 195 SUCTION ACCUMULATOR OPERATION Liquid refrigerant collects in the suction accumulator during the harvest cycle and is removed during the freeze cycle. The liquid refrigerant is returned to the compressor through a screen and orifice in the suction accumulator J tube. Passing the liquid through the orifice causes a pressure drop; the liquid flashes to a vapor and creates a refrigeration affect. It is normal to see frost on the accumulator, suction line and compressor suction port in the freeze cycle. The suction accumulator empties within the first 5 minutes of the freeze cycle. When the refrigeration affect ends (liquid refrigerant has been removed), the suction line between the accumulator and compressor will increase in temperature. The suction line temperature increases 20 plus degrees within 2 minutes after the liquid has been removed. Temperature Increases 20+ºF (18+ºC) 6 Minutes 1 Minute 2 Minutes 3 Minutes 4 Minutes 7 Minutes 8 Minutes 5 Minutes The time needed to remove the liquid refrigerant will vary with the ambient temperature and the length of the harvest cycle. Higher ambient temperatures = shorter harvest cycles, faster removal of liquid refrigerant from the accumulator and greater suction line temperature increases. 196 Part Number STH026 8/12 Recovery/Evacuation/Charging Procedures QUIETQUBE® MODELS Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important Manitowoc Ice assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company. Important Replace the liquid line drier after recovering the refrigerant and before evacuating and recharging. Use only a Manitowoc (OEM) liquid line filter-drier to prevent voiding the warranty. ! Warning Recovery/evacuation of a QuietQube® remote system requires connections at five points for complete system recovery/evacuation. Check valves are located in the ice machine head section and the ICVD condensing unit. Five point requires connections between the compressor and suction filter access valve, receiver access valve and the high and low side access valves on the front or rear of the ice machine to recover and evacuate the entire system. ! Warning The receiver access valve (located in the ice machine head section) must be accessed during refrigerant recovery to allow complete removal of the refrigerant charge. Part Number STH026 8/12 197 CONNECTIONS Manifold gauge sets must utilize low loss fittings to comply with U.S. Government rules and regulations. Make these connections: Ice Machine Head Section - All Models 1. Suction side of the compressor through the suction shut-off valve or suction access valve. 2. Discharge side of the compressor through the liquid line shut-off valve or high side access valve. 3. Receiver access valve, which evacuates the area between the check valve in the liquid line and the liquid line solenoid valve.. ! Warning Recovery/evacuation of a QuietQube® remote system requires connections at three points for complete system recovery/evacuation. Check valves are located in the ice machine head section and the ICVD condensing unit. Three point requires connections between the receiver access valve and the high and low side access valves on the front or rear of the ice machine to recover and evacuate the entire system CONNECTIONS MUST BE MADE AT THREE POINTS ON HEAD SECTION FOR COMPLETE REFRIGERANT RECOVERY ON ALL QUIETQUBE® MODELS. Refrigerant Recovery Connections Ice Machine Head 198 Part Number STH026 8/12 RECOVERY/EVACUATION PROCEDURES 1. Press the power button to stop the ice machine. and disconnect all power to the ice machine and condensing unit. 2. Install manifold gauges, charging scale, and recovery unit or two-stage vacuum pump. 3. Open high and low side on the manifold gauge set. 4. Perform recovery or evacuation: A. Recovery: Operate the recovery unit as directed by the manufacturer’s instructions. B. Pressure test the system. C. Evacuation prior to recharging: Evacuate to 500 microns. Then allow the pump to run for an additional hour. 5. Refer to Charging Procedures. Part Number STH026 8/12 199 CHARGING PROCEDURES 1. The ice machine must be off. 2. Close the vacuum pump valve and the low side manifold gauge valve. 3. Open the refrigerant cylinder and add the proper refrigerant charge (shown on nameplate) into the system high side (receiver service valve and discharge line shut-off valve). 4. If the high side does not take the entire charge, close the high side on the manifold gauge set. Start the ice machine and wait until the freeze cycle starts, then add the remaining charge through valves on back of ice making head, or through valves on suction filter.. 5. Disconnect the manifold gauge set from the liquid line shut-off valve. 6. Open the high and low side valves on the manifold gauge set. Any refrigerant in the lines will be pulled into the low side of the system. 7. Allow the pressures to equalize while the ice machine is in the freeze cycle. 8. Disconnect the manifold gauge set from the suction line shut-off valve. 9. Install and torque all valve caps NOTE: Check for refrigerant leaks after all valve caps have been installed. 200 Part Number STH026 8/12 System Contamination Clean-Up General This section describes the basic requirements for restoring contaminated systems to reliable service. Important Manitowoc Ice assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company. DETERMINING SEVERITY OF CONTAMINATION System contamination is generally caused by either moisture or residue from compressor burnout entering the refrigeration system. Inspection of the refrigerant usually provides the first indication of system contamination. Obvious moisture or an acrid odor in the refrigerant indicates contamination. If either condition is found, or if contamination is suspected, use a Total Test Kit from Totaline or a similar diagnostic tool. These devices sample refrigerant, eliminating the need to take an oil sample. Follow the manufacturer’s directions. If a refrigerant test kit indicates harmful levels of contamination, or if a test kit is not available, inspect the compressor oil. 1. Remove the refrigerant charge from the ice machine. 2. Remove the compressor from the system. 3. Check the odor and appearance of the oil. 4. Inspect open suction and discharge lines at the compressor for burnout deposits. 5. If no signs of contamination are present, perform an acid oil test. Check the chart on the next page to determine the type of cleanup required. Part Number STH026 8/12 201 Contamination Cleanup Chart Symptoms/Findings No symptoms or suspicion of contamination Moisture/Air Contamination symptoms Refrigeration system open to atmosphere for longer than 15 minutes Refrigeration test kit and/or acid oil test shows contamination Leak in water cooled condenser No burnout deposits in open compressor lines Mild Compressor Burnout symptoms Oil appears clean but smells acrid Refrigeration test kit or acid oil test shows harmful acid content No burnout deposits in open compressor lines Severe Compressor Burnout symptoms Oil is discolored, acidic, and smells acrid Burnout deposits found in the compressor, lines, and other components 202 Required Cleanup Procedure Normal evacuation/recharging procedure Mild contamination cleanup procedure Mild contamination cleanup procedure Severe contamination cleanup procedure Part Number STH026 8/12 CLEANUP PROCEDURE Mild System Contamination 1. Replace any failed components. 2. If the compressor is good, change the oil. 3. Replace the liquid line drier. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation. Do not position heat lamps too close to plastic components, or they may melt or warp. Important Dry nitrogen is recommended for this procedure. This will prevent CFC release. 4. Follow the normal evacuation procedure, except replace the evacuation step with the following: A. Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psig (35 kPa,.35 bar). B. Pull vacuum to 500 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psig (35 kPa,.35 bar). C. Change the vacuum pump oil. D. Pull vacuum to 500 microns. Run the vacuum pump for 1 hour. NOTE: You may perform a standing vacuum test to make a preliminary leak check. You should use an electronic leak detector after system charging to be sure there are no leaks. 5. Charge the system with the proper refrigerant to the nameplate charge. 6. Operate the ice machine. Part Number STH026 8/12 203 Severe System Contamination 1. Remove the refrigerant charge. 2. Remove the compressor and inspect the refrigeration lines. If burnout deposits are found, install a new harvest valve, replace the manifold strainer, TXV and harvest pressure regulating valve. 3. Wipe away any burnout deposits from suction and discharge lines at compressor. 4. Sweep through the open system with dry nitrogen. Important Refrigerant sweeps are not recommended, as they release CFCs into the atmosphere. 5. Install a new compressor and new start components. 6. Install a suction line filter-drier with acid and moisture removal capability. Place the filter drier as close to the compressor as possible. 7. Install an access valve at the inlet of the suction line drier. 8. Install a new liquid line drier (and suction filter on QuietQube® condensing units). 204 Part Number STH026 8/12 Important Dry nitrogen is recommended for this procedure. This will prevent CFC release. 9. Follow the normal evacuation procedure, except replace the evacuation step with the following: A. Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psig (35 kPa,.35 bar). B. Change the vacuum pump oil. C. Pull vacuum to 500 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psig (35 kPa,.35 bar). D. Change the vacuum pump oil. E. Pull vacuum to 500 microns. Run the vacuum pump for 1 hour. NOTE: You may perform a standing vacuum test to make a preliminary leak check. You should use an electronic leak detector after system charging to be sure there are no leaks. 10. Charge the system with the proper refrigerant to the nameplate charge. 11. Operate the ice machine for one hour. Then, check the pressure drop across the suction line filter-drier. A. If the pressure drop is less than 1 psig (7 kPa,.7 bar), the filter-drier should be adequate for complete cleanup. B. If the pressure drop exceeds 1 psig (7 kPa,.7 bar), change the suction line filter-drier and the liquid line drier. Repeat until the pressure drop is acceptable. 12. Operate the ice machine for 48-72 hours. Then remove the suction line drier and change the liquid line drier. 13. Follow normal evacuation procedures. Part Number STH026 8/12 205 REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE This procedure reduces repair time and cost. Use it when any of the following components require replacement, and the refrigeration system is operational and leak-free. • Fan cycle control (air cooled only) • Water regulating valve (water cooled only) • High pressure cut-out control • Low Pressure cut-out control • High side service valve • Low side service valve Important This is a required in-warranty repair procedure. 1. Disconnect power to the ice machine. 2. Follow all manufacturer’s instructions supplied with the pinch-off tool. Position the pinch-off tool around the tubing as far from the pressure control as feasible. (See the figure on next page.) Clamp down on the tubing until the pinch-off is complete. ! Warning Do not unsolder a defective component. Cut it out of the system. Do not remove the pinch-off tool until the new component is securely in place. 206 Part Number STH026 8/12 USING PINCH-OFF TOOL 3. Cut the tubing of the defective component with a small tubing cutter. 4. Solder the replacement component in place. Allow the solder joint to cool. 5. Remove the pinch-off tool. 6. Re-round the tubing. Position the flattened tubing in the proper hole in the pinch-off tool. Tighten the wing nuts until the block is tight and the tubing is rounded. NOTE: The pressure controls will operate normally once the tubing is re-rounded. Tubing may not reround 100%. Part Number STH026 8/12 207 LIQUID LINE FILTER-DRIERS The filter-driers used on Manitowoc ice machines are manufactured to Manitowoc specifications. A Manitowoc drier has dirt-retaining filtration, with fiberglass filters on both the inlet and outlet ends. This is very important because ice machines have a backflushing action that takes place during every Harvest cycle. The size of the filter-drier is important. The refrigerant charge is critical. Using an improperly sized filter-drier will cause the ice machine to be improperly charged with refrigerant. Important Driers are covered as a warranty part. The drier must be replaced any time the system is opened for repairs. SUCTION FILTER The suction filter on QuietQube® ICVD condensing units traps particulate only, and do not contain a desiccant. The filter needs replacement when: 1. The pressure drop across the drier exceeds 2 psig. 2. A compressor is replaced. 3. Refrigeration system contains contaminants. 208 Part Number STH026 8/12 TOTAL SYSTEM REFRIGERANT CHARGE NOTE: All machines listed use R-404A refrigerant This information is for reference only. Refer to the ice machine serial number tag to verify the system charge. Serial plate information overrides information listed on these pages. QuietQube® ICVD Models Model I0680C I0680C IB0690C I0870C IB0890C I1070C IB1090C I1470C I1870C I2170C Condensing Unit ICVD0695 ICVD0895 ICVD0895 ICVD1095 ICVD1195 ICVD1495 ICVD1895 ICVD2095 Part Number STH026 8/12 Refrigerant Charge Line Set Length 10.75 lbs. 4.88kg. 0-50 ft. 0-15 M 12.25 5.55 kg. 51-100 ft. 15-30 M 11 lbs. 5 kg. 0-50 ft. 0-15 M 15 lbs. 6.8 kg 51-100 ft. 15-30 M 11 lbs. 5 kg 0-50 ft. 0-15 M 13 lbs. 5.9 kg 51-100 ft. 15-30 M 10 lbs. 4.5 kg 0-50 ft. 0-15 M 12 lbs 5.44 kg 51-100 ft. 15-30 M 12 lbs. 5.44 kg 0-50 ft. 0-15 M 14 lbs 6.35 kg 51-100 ft. 15-30 M 12.75 lbs. 5.8 kg 0-50 ft. 0-15 M 14.75 lbs 6.69 kg 51-100 ft. 15-30 M 15 lbs. 6.8 kg 0-50 ft. 0-15 M 17 lbs 7.71 kg 51-100 ft. 15-30 M 18 lbs. 8.16 kg 0-50 ft. 0-15 M 22 lbs 9.97kg 51-100 ft. 15-30 M 209 This Page Intentionally Left Blank 210 Part Number STH026 8/12 Charts Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts These charts are used as guidelines to verify correct ice machine operation. Accurate collection of data is essential to obtain the correct diagnosis. • Production and cycle times are for dice cube - Half dice cube cycle times can be 2 - 3 minutes faster, depending on model and ambient temperature. • Regular cube production derate is 7%. • Ice production checks that are within 10% of the chart are considered normal. This is due to variances in water and air temperature. Actual temperatures will seldom match the chart exactly. • Refer to “Symptom #2 - Operational Analysis Table” page 121 for the list of data that must be collected for refrigeration diagnostics. • Zero out manifold gauge set before obtaining pressure readings to avoid misdiagnosis. • Discharge and suction pressure are highest at the beginning of the cycle. Suction pressure will drop throughout the cycle. Verify the pressures are within the range indicated. • Record beginning of freeze cycle suction pressure one minute after water pump energizes. • 50Hz dice and half dice production derate is 12%. • 50Hz regular cube total production derate is 14%. Part Number STH026 8/12 211 I0680C/ICVD0695 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 70/21 90/32 -20 to 70/ -29 to 21 8.7-10.0 10.8-12.4 12.3-14.1 90/32 10.3-11.9 11.6-13.3 12.4-14.3 100/38 11.0-12.6 12.2-13.9 13.4-15.3 110/43 12.0-13.8 13.4-15.3 14.9-17.0 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 650 540 480 90/32 560 505 475 100/38 530 485 445 110/43 490 445 405 1Based on average ice slab weight of 4.60 - 5.20 lb. OPERATING PRESSURES Freeze Cycle Harvest Cycle Air Temp. Entering Condenser °F/°C Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 200-250 44-26 180-210 65-85 70/21 235-255 50-28 185-210 65-90 80/27 245-275 50-28 190-210 75-100 90/32 250-290 52-30 195-215 75-105 100/38 270-320 52-31 210-240 80-110 110/43 300-360 60-32 215-260 85-115 212 Part Number STH026 8/12 IB0690C/ICVD695 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C 50/10 -20 to 70/ -29 to 21 8.9-10.2 9.5-11.0 1.3-11.9 80/27 9.3-10.7 10.0-11.5 10.9-12.5 90/32 9.6-11.1 10.4-12.0 11.4-13.0 100/38 10.2-11.8 11.1-12.8 12.2-13.9 110/43 11.0-12.6 12.0-13.8 13.2-15.1 1Times Freeze Time Harvest Time Water Temperature °F/°C 70/21 90/32 .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 640 600 560 80/27 615 575 535 90/32 595 555 515 100/38 565 525 485 110/43 530 490 450 1Based on average ice slab weight of 4.60 - 5.20 lb. OPERATING PRESSURES Freeze Cycle Harvest Cycle Air Temp. Entering Condenser °F/°C Discharge Pressure psig Suction Pressure psig Discharge Pressure psig -20 to 50/ -29 to 10 215-260 46-26 140-185 70-95 70/21 220-270 51-26 150-190 70-100 80/27 225-285 56-27 155-195 80-105 90/32 235-295 59-28 165-200 85-105 100/38 260-340 60-30 180-210 85-112 110/43 300-385 65-34 195-230 90-120 Part Number STH026 8/12 Suction Pressure psig 213 I0870C/ICVD895 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 70/21 90/32 -20 to 70/ -29 to 21 11.0-12.6 12.1-13.8 13.4-15.4 90/32 12.5-14.4 12.8-14.6 14.9-17.0 100/38 13.6-15.5 14.7-16.9 1539-18.2 110/43 14.9-16.9 15.8-18.0 16.9-19.3 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 665 610 555 90/32 590 580 505 100/38 550 510 475 110/43 510 480 450 1Based on average ice slab weight of 5.75-6.50 lb. OPERATING PRESSURES Freeze Cycle Harvest Cycle Air Temp. Entering Condenser °F/°C Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 200-250 50-30 170-200 65-75 70/21 250-290 60-30 180-210 75-95 80/27 260-300 60-31 190-220 75-95 90/32 270-310 60-33 200-230 80-100 100/38 300-380 80-34 210-250 90-110 110/43 310-390 80-35 220-260 105-130 214 Part Number STH026 8/12 IB0890C/ICVD895 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time -20 to 70/ -29 to 21 50/10 70/21 90/32 8.5-9.8 9.3-10.7 10.0-11.5 90/32 9.5-11.0 10.8-12.4 11.4-13.1 100/38 11.2-12.9 12.3-14.1 13.3-15.2 110/43 13.0-14.9 14.0-16.0 14.9-17.0 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 825 770 720 90/32 750 675 640 100/38 650 600 560 110/43 570 535 505 1Based on average ice slab weight of 5.75-6.50 lb. OPERATING PRESSURES Air Temp. Entering Condenser °F/°C Freeze Cycle Harvest Cycle Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 230-260 45-25 180-205 60-80 70/21 250-275 55-30 180-205 75-105 80/27 260-290 60-31 185-215 80-110 90/32 265-300 60-32 190-220 80-110 100/38 300-370 70-34 200-250 90-115 110/43 310-385 75-35 230-260 95-115 Part Number STH026 8/12 215 I1070C/ICVD1095 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 70/21 90/32 11.1-13.1 -20 to 70/ -29 to 21 7.9-9.4 9.7-11.5 80/27 8.4-10.0 10.2-12.1 11.6-13.7 90/32 8.9-10.6 10.8-12.8 12.3-14.6 100/38 9.5-11.3 11.4-13.5 13.1-15.5 110/43 9.9-11.8 12.0-14.2 13.9-16.4 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 950 800 710 80/27 900 760 680 90/32 860 725 645 100/38 810 690 610 110/43 780 660 580 1Based on average ice slab weight of 6.2 - 7.2 lb. OPERATING PRESSURES Freeze Cycle Harvest Cycle Air Temp. Entering Condenser °F/°C Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 200-250 40-30 155-180 70-85 70/21 230-255 50-30 155-180 70-90 80/27 235-260 50-30 155-180 70-95 90/32 240-290 55-31 155-180 85-105 100/38 275-345 60-32 160-200 90-115 110/43 310-380 65-32 160-210 100-120 216 Part Number STH026 8/12 IB1090C/ICVD1195 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 70/21 90/32 -20 to 70/ -29 to 21 9.3-10.7 10.1-11.7 11.1-12.7 80/27 10.1-11.7 11.1-12.7 11.8-13.6 90/32 10.9-12.6 12.2-14.0 12.7-14.6 100/38 12.0-13.8 12.9-14.8 13.7-15.7 110/43 13.1-15.0 13.9-16.0 14.9-17.1 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 1000 930 860 80/27 930 860 810 90/32 870 790 760 100/38 800 750 710 110/43 740 700 660 1Based on average ice slab weight of 7.5 - 8.5 lb. OPERATING PRESSURES Air Temp. Entering Condenser °F/°C Freeze Cycle Harvest Cycle Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 200-250 40-25 140-170 65-75 70/21 220-270 40-25 150-185 65-85 80/27 225-275 50-26 160-190 70-90 90/32 235-275 60-27 175-195 75-95 100/38 260-325 65-30 190-220 80-100 110/43 300-360 70-33 200-230 90-105 Part Number STH026 8/12 217 I1470C/ICVD1495 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 70/21 90/32 -20 to 70/ -29 to 21 11.5-13.7 12.5-14.8 14.5-17.2 80/27 13.0-15.4 14.0-16.6 16.3-19.3 90/32 14.1-16.7 16.1-19.1 17.5-20.7 100/38 15.0-17.8 17.3-20.4 18.7-22.1 110/43 11.5-13.7 12.5-14.8 14.5-17.2 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 1330 1235 1080 90/32 1190 1115 970 100/38 1110 980 910 110/43 1045 920 855 1Ice slab weight of one harvest cycle = 12.0 lb. to 14.0 lb. 6.0 to 7.0 lbs per evaporator 5.44 kg to 6.35 kg (2.72 to 3.18 kg per evaporator) 230/50/1 is approximately 12% lower than 230/60/1. OPERATING PRESSURES Air Temp. Entering Condenser °F/°C Freeze Cycle Harvest Cycle Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 250-235 60-36 140-165 70-95 70/21 250-235 60-38 150-170 70-95 80/27 275-240 60-38 160-180 85-95 90/32 300-285 65-39 170-190 90-110 100/38 350-300 70-40 180-200 95-115 110/43 410-350 80-40 190-215 100-125 218 Part Number STH026 8/12 I1870C/ICVD1895 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 70/21 90/32 -20 to 70/ -29 to 21 11.5-12.6 15.5-14.4 14.3-15.6 80/27 13.2-14.4 14.7-16.0 16.5-18.0 90/32 14.3-15.5 16.4-17.8 17.7-19.3 100/38 15.4-16.8 17.7-19.3 19.3-20.9 110/43 11.5-12.6 15.5-14.4 14.3-15.6 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 1715 1520 1410 1240 90/32 1520 1375 100/38 1415 1250 1160 110/43 1320 1160 1075 1Ice slab weight of one harvest cycle = 15.5 lb. to 16.75 lb. 7.75 - 8.38 lb per evaporator 7.0 kg to 7.6 kg (3.5 to 3.8 kg per evaporator) 230/50/1 is approximately 12% lower than 230/60/1 OPERATING PRESSURES Air Temp. Entering Condenser °F/°C Freeze Cycle Harvest Cycle Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 215-250 60-30 140-155 65-90 70/21 215-260 60-33 140-155 65-90 80/27 240-280 60-34 145-165 65-95 90/32 250-295 60-35 150-170 65-95 100/38 290-365 60-36 160-190 75-100 110/43 300-380 60-37 170-200 80-110 Part Number STH026 8/12 219 I2170C/ICVD2195 Remote Air-Cooled Condensing Unit Model Characteristics vary depending on operating conditions. CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Cycle Time Air Temp. Entering Condenser °F/°C Freeze Time 50/10 -20 to 70/ -29 to 21 80/27 70/21 90/32 10.7-11.6 11.7-12.8 12.5-13.7 11.0-12.1 12.5-13.7 13.4-14.6 90/32 12.1-13.2 12.9-14.0 14.4-15.7 100/38 12.5-13.7 14.4-15.7 15.6-17.0 110/43 13.4-14.6 15.6-17.0 16.9-18.4 1Times Harvest Time Water Temperature °F/°C .75-2.5 in minutes - Dice cube 24-HOUR ICE PRODUCTION Air Temp. Entering Condenser °F/°C Water Temperature °F/°C 50/10 70/21 90/32 -20 to 70/ -29 to 21 1835 1685 1590 80/27 1780 1590 1495 90/32 1640 1555 1400 100/38 1590 1400 1305 110/43 1495 1305 1210 1Ice slab weight of one harvest cycle = 15.5 lb. to 16.75 lb. 7.75 - 8.38 lb per evaporator 7.0 kg to 7.6 kg (3.5 to 3.8 kg per evaporator) 230/50/1 is approximately 12% lower than 230/60/1. OPERATING PRESSURES Freeze Cycle Harvest Cycle Air Temp. Entering Condenser °F/°C Discharge Pressure psig Suction Pressure psig Discharge Pressure psig Suction Pressure psig -20 to 50/ -29 to 10 200-250 45-28 125-140 70-80 70/21 200-260 50-28 125-160 70-80 80/27 220-275 50-28 130-180 70-90 90/32 260-315 58-30 150-190 70-100 100/38 300-360 65-30 160-200 80-110 110/43 320-400 70-30 170-210 90-120 220 Part Number STH026 8/12 Diagrams Wiring Diagrams The following pages contain electrical wiring diagrams. Be sure you are referring to the correct diagram for the ice machine you are servicing. ! Warning Always disconnect power before working on electrical circuitry. Some components are wired differently on energy efficient machines. Please verify your model number (page 19) to reference the correct diagrams. WIRING DIAGRAM LEGEND The following symbols are used on all of the wiring diagrams: * Internal Compressor Overload (Some models have external compressor overloads) ** Fan Motor Run Capacitor (Some models do not incorporate fan motor run capacitor) ( ) Wire Number Designation (The number is marked at each end of the wire) —>>— Multi-Pin Connection (Electrical Box Side) —>>— (Compressor Compartment Side) Part Number STH026 8/12 221 222 HPCO Detection iCVD Relay LPCO Detection Ice Machine HPC2 HPC1 LPC C V HPCO C 24V 230V -24V Transformer 24 Volt Contactor Coil LPCO iCVD Condensing Unit L2 L1 ALL ICVD MODELS INTERCONNECTING WIRING Part Number STH026 8/12 I0670C/I0870C/I1070C/I1270C QuietQube® Remote Air-cooled - 1 & 3 Ph Part Number STH026 8/12 223 IB0690C/IB0890C/IB1090C QuietQube® Remote Air-cooled - 1 & 3 Ph 224 Part Number STH026 8/12 II1400/I1800/I2170 QuietQube® Remote Air-cooled 1 & 3 Ph Part Number STH026 8/12 225 ICVD2095 QuietQube® Remote Air-cooled 3 Ph 226 Part Number STH026 8/12 Electronic Control Board Bin Switches Bin Thermostat USB Display Light Micro Light Clean Light Harvest Light SL-1 Light SL-2 Light Thermistors T1 T2 Dump Valve T3 T4 Left Bin Switch Light Transformer Right Bin Switch Light Water Level Probe Light Display Ice Thickness Probe Light RS485 RT Harvest Bin LED LuminIce Battery Compressor LT Harvest Water Level Probe Fuse Relay Lights Pump Water Pump AuCS Water Remote CVD V C LPC HPC1 HPC2 Ice Thickness Probe Compressor L1 Dump L2 Not Used CVD Contactor HPC Right Harvest Valve Water Inlet Valve Part Number STH026 8/12 Left Harvest Valve Dump Valve 227 Refrigeration Tubing Schematics REMOTE CONDENSING UNIT MODELS I0670C/I0870C/I1070C/I1270C Condensing Unit SUCTION LINE FILTER COMPRESSOR ACCESS VALVE CHECK VALVE CONDENSER ACCUMULATOR HEAD PRESSURE CONTROL VALVE S TRAP REQUIRED 21’ OR GREATER RISE LIQUID LINE SHUT-OFF VALVE SUCTION SHUT-OFF VALVE Ice Machine Head Section EVAPORATOR HEAT EXCHANGER T4 Thermistor TXV T3 Thermistor LLSV HARVEST VALVE DRIER CHECK VALVE RECEIVER ACCESS VALVE T1 Thermistor RECEIVER T2 Thermistor 228 Part Number STH026 8/12 IB MODELS IB0690C/IB0890C Condensing Unit SUCTION LINE FILTER COMPRESSOR ACCESS VALVE CHECK VALVE CONDENSER ACCUMULATOR HEAD PRESSURE CONTROL VALVE S TRAP REQUIRED 21’ OR GREATER RISE LIQUID LINE SHUT-OFF VALVE SUCTION SHUT-OFF VALVE Ice Machine Head Section EVAPORATOR HEAT EXCHANGER T4 Thermistor TXV T3 Thermistor LLSV HARVEST VALVE DRIER CHECK VALVE RECEIVER ACCESS VALVE T1 Thermistor RECEIVER T2 Thermistor Part Number STH026 8/12 229 IB1090C COMPRESSOR SUCTION LINE FILTER ACCESS VALVE CHECK VALVE CONDENSER ACCUMULATOR S TRAP REQUIRED 21’ OR GREATER RISE HEAD PRESSURE CONTROL VALVE Ice Machine Head Section LIQUID LINE SHUT-OFF VALVE EVAPORATOR HARVEST VALVE SUCTION SHUT-OFF VALVE TXV HEAT EXCHANGER LLSV DRIER TXV HARVEST VALVE CHECK VALVE RECEIVER 230 Part Number STH026 8/12 DUAL EVAPORATOR MODELS I1470C/I1870C ACCESS VALVE CHECK VALVE SUCTION FILTER CONDENSER ACCUMULATOR COMPRESSOR HEAD PRESSURE CONTROL VALVE S Trap Required 21’ or Greater Rise SUCTION SHUT-OFF VALVE LIQUID LINE SHUT-OFF VALVE T4 Thermistor T3 Thermistor HEAT EXCHANGER EVAPORATOR EVAPORATOR TXV LLSV HARVEST VALVE HARVEST VALVE DRIER CHECK VALVE RECEIVER ACCESS VALVE RECEIVER T1 Thermistor T2 Thermistor Part Number STH026 8/12 231 I2170C SUCTION FILTER COMPRESSOR CONDENSER ACCUMULATOR HEAD PRESSURE CONTROL VALVE S Trap Required 21’ or Greater Rise SUCTION SHUT-OFF VALVE LIQUID LINE SHUT-OFF VALVE T4 Thermistor T3 Thermistor EVAPORATOR HEAT EXCHANGER EVAPORATOR TXV LLSV HARVEST VALVE HARVEST VALVE DRIER CHECK VALVE RECEIVER ACCESS VALVE RECEIVER T1 Thermistor T2 Thermistor 232 Part Number STH026 8/12 This Page Intentionally Left Blank Part Number STH026 8/12 233 234 Part Number STH026 8/12 Manitowoc Ice 2110 South 26th Street, P.O. Box 1720 Manitowoc, WI 54221-1720, USA Ph: 920-682-0161 Fax: 920-683-7589 Visit us online at: www.manitowocice.com © 2012 Manitowoc Part Number STH026 8/12